Advanced Forming Processes Super plastic Forming

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  • Advanced Forming Processes Super plastic Forming
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  • Ahmed Rabea Ibrahim Sayed Ahmed Mohamed Saber Salama Alaa Kamel Hossam Gamal Karim Mohamed Khaled Mohamed Hassan Mohamed Mohamed Ramdan Mohsen Eid Mohamed Ali Ibrahim Mohamed
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  • SUPERPLASTIC FORMING DEFINITION A process for shaping super-plastic materials, a unique class of crystalline materials that exhibit exceptionally high ductility with neck- free elongation. In specific, SPF is a hot forming process in which sheets of superplastic grade aluminum are heated and forced onto or into single surface tools by air pressure.
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  • Superplastic materials may be stretched in tension to elongations typically in excess of 200% and more commonly in the range of 400 2000%. There are rare reports of higher tensile elongations reaching as much as 8000%. The high ductility is obtained only for superplastic materials and requires both the temperature and rate of deformation (strain rate) to be within a limited range.
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  • Video 1
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  • Super plastic Forming Processes Super plastic Forming Processes Cavity Forming This forming process is suitable for the manufacturing of parts with smooth, convex surfaces. Bubble Forming the bubble forming technology is particularly suitable for parts with high forming depths. Diaphragm Forming the diaphragm-forming method (DFM) can be used to reduce the tensile flow stress generated in a specific alloy matrix composite during deformation.
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  • Types of forming superplastic sheet materials: Types of forming superplastic sheet materials: Blow/vacuum forming Thermo-forming Deep drawing Superplastic forming/diffusion bonding (SPF/DB)
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  • Production Process: SPF Need presses 1000, 3000and 8000kN SPF/HGPF allows complex shape design with Hi-strength alloys
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  • SPF is a Gas pressure forming process(HGPF)
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  • Typical SPF/ HGPF-Sample Geometries 1.Magnesium ~ AZ 31, MA 2-1, etc. 2.Aluminium ~ AA 5083, 7475, etc. 3.Titanium ~Ti 6-4, BT6, BT6-S, Ti6-2- 4-2, 4. 21 S, SP 700, Ti 6-22-22, Ti-MMC 5.Ti-Al ~ gamma TiAl 6.Steel ~ 1.4462, Lean duplex, etc. 7.Nickel ~ IN 718
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  • APPLICATIONS
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  • Aerospace - Lightweight Laminar Structures Lip Skins Engine Nacelle Skins Bulkheads Lamp Drums Wing Tips Winglets Leading Edge Ribs Access Door Inner Skins Equipment Covers Facia panels Acoustic Panels SPF parts in Al alloy, from Superform website SPF/DB parts in titanium alloy, Courtesy from Dassault
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  • Automotive - Enclosures, Body in White, Chassis Structures Door Inners Bodysides Door Rings Enclosure assemblies Tunnels B Pillars Cantrails Roof Structures Bulkheads Footwells Exterior Body Panels SPF parts in Al alloy, from Superform website
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  • Rail - Cab Structures, Interior Panels, Doors and Seating Cab Skins Cab Structures Cab Desks Inter End Skins Inter End Canopies Interior Window Masks Interior Doorway Panels Cab Interiors Door Systems SPF parts in Al alloy, from Superform website
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  • Architectural Cladding, Bullnose, Ceiling and Acoustic Panels Example of decorative panels Roof panels of the Charlty stadium in Paris
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  • Application in sports Application in furniture Application in arts Additional sectors of application
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  • Medical
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  • Tools for SPF forming Example of non metallic tool for SPF Lid of metallic container for SPF
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  • Production Process: Diffusion Bonding
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  • DB of Plates;e.g. Heat Exchangers
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  • SPF/DB* Sandwich Design
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  • SPF/DB Sandwich Design
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  • Vessel manufacturing
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  • ADVANTAGES 1. Complex shapes are easily made 2.Flexibility in design. 3. Low applied stress for forming HSLA materials. 4.Low capital cost on equipments. 5.Effective material utilization and savings.
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  • DISADVANTAGES 1.Inferior creep resistance 2.Very slow process.
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