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I I10/10/2019Confidential 1
Formability of Titanium Ti-6Al-4V sheets
at low temperature
Sture Olsson
Quintus Technologies
Business Development Manager, Sheet Metal Forming
October 9, 2019
MEMBER OF KOBE STEEL GROUP
AEROSPACE TECHNOLOGY CONGRESS 2019
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Formability of Titanium Ti-6Al-4V sheets at low
temperature
• Introduction
• Warm Forming of Titanium 6Al-4V
• Initial lab results
• Production process validation
10/10/2019Confidential 2 MEMBER OF KOBE STEEL GROUP
I I10/10/2019Confidential 3
150KTon
2000Bar
CAPABLE OF EXPERTS IN CERTIFIED BY
HIGH PRESSURE
MEMBER OF KOBE STEEL GROUP
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Foundation and history of excellence
200519991995199119641953 1965 1988
Introduction of
Quintus Food presses
Introduction of
Quintus Metal
Forming presses
Introduction of
Quintus Isostatic
pressesCompany produces the world’s
first synthetic diamond
1940-
1950
Company formation
2009
Sale of Company to
Flow International
Joint venture
with BBC
2013 2014 2017
10/10/2019
1886
High
pressure
R&D
MEMBER OF KOBE STEEL GROUP
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The Flexform Sheet Metal Forming Technology
• Historically a cold forming process
• Using one shape defining tool half
• Second tool half being a flexible rubber diaphragm, backed up by hydraulic pressure
• Blank thickness from thin foil to some 15 mm stainless steel maybe formed
10/10/2019Confidential 6 MEMBER OF KOBE STEEL GROUP
Click: https://www.youtube.com/watch?v=m0HtZq9pokY
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Typical Cold Formed Parts – Airframes
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• Shrink and stretch flanges
• Double curved
• Recessed parts
MEMBER OF KOBE STEEL GROUP
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Typical Flexform Parts – Jet engines
• Deep parts
• Tough alloys, typically
Inconel and Titanium
• Severe tolerance and
quality demand
MEMBER OF KOBE STEEL GROUP
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Examples - Customers & Partners
10/10/2019Confidential 9 MEMBER OF KOBE STEEL GROUP
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Formability of Titanium Ti-6Al-4V sheets at low
temperature
• Introduction
• Warm Forming of Titanium 6Al-4V
• Initial lab results
• Production process validation
10/10/2019Confidential 10 MEMBER OF KOBE STEEL GROUP
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Why?
• Growing need for Ti 6Al-4V due to the composite
growth
• Need for a competitive process vs. various hot
forming processes
• Perceived hot forming challenges:
• High energy cost
• High tooling cost
• Slow process, low productivity and low capacity
• Poor process control
• Labor dependent
10/10/2019Confidential 11 MEMBER OF KOBE STEEL GROUP
Current hot forming processes
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Hot vs. Warm Forming
0
200
400
600
800
1000
1200
1400
Hot forming
HPWF
Pressure, temperature & time
Temperature, C Pressure, bar Time, min.
10/10/2019Confidential 12
Hot Forming Processes High Pressure Warm Forming
600-900°C 270°C
<10 bar 1400 bar / 140 MPa
-120 min <5 min
MEMBER OF KOBE STEEL GROUP
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Formability of Titanium Ti-6Al-4V sheets at low
temperature
• Introduction
• Warm Forming of Titanium 6Al-4V
• Initial lab results
• Production process validation
10/10/2019Confidential 13 MEMBER OF KOBE STEEL GROUP
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High Pressure Warm Forming
10/10/2019Confidential 14 MEMBER OF KOBE STEEL GROUP
2014-04559
Pre-study funding
Warm forming of Titanium
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Initial lab test conclusions
Springback reduction
• Springback reduced with 20% in bending tests
• Lab cases indicate bigger reduction
10/10/2019Confidential 15
0
5
10
15
20
25
30
RT 270 C
Spri
ngback d
egre
es
Temperature
Bending test
RT
270°C
RT = Room temperature
MEMBER OF KOBE STEEL GROUP
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HPWF - Part forming suitability
10/10/2019Confidential 16
Part configuration
deemed suitable for
the HPWF process
MEMBER OF KOBE STEEL GROUP
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Expected process benefits
10/10/2019Confidential 17 MEMBER OF KOBE STEEL GROUP
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Reduce production cost
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0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
SPF
Hot Forming
Quintus
Production time/part
Pre-form Pressing Part Cool down * Data from: Advanced Forming Research Centre
(AFRC), University of Strathclyde
*
* SPF = Super Plastic Forming
MEMBER OF KOBE STEEL GROUP
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Increase productivity
10/10/2019Confidential 19
140,000 parts
23,000 parts
2,500 parts
Quintus: 3 parts/cycle
HS/SPF: 1 part/cycle
2 shifts and 240 days/year0 20000 40000 60000 80000 100000 120000 140000
SPF
Hot Forming
Quintus
Production output, parts/year
MEMBER OF KOBE STEEL GROUP
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Reduce production cost
10/10/2019Confidential 20
0% 20% 40% 60% 80% 100%
SPF
Hot Forming
Quintus
Production cost
Material cost Labour cost Other
*
*
* Data from: Advanced Forming Research Centre
(AFRC), University of Strathclyde
MEMBER OF KOBE STEEL GROUP
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High Pressure Warm Forming
10/10/2019Confidential 21 MEMBER OF KOBE STEEL GROUP
2015-05196
Process demo project funding
High-pressure process for Titanium
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Lab scale warm forming system
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• Scalable
• Automation
• Process control
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Demo parts – Lab scale
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• With and without springback compensation
MEMBER OF KOBE STEEL GROUP
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Demo parts – Lab scale
10/10/2019Confidential 24
• Shrink & stretch flanges
• Joggles
• Gentle curvatures
MEMBER OF KOBE STEEL GROUP
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Lab test conclusions – Excellent forming repeatability
10/10/2019Confidential 25 MEMBER OF KOBE STEEL GROUP
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Test sample
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Extracted Samples for Section 2
ID 30 ID M
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Section sample mounted
Left (End) side
Right (Flat) side
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Macro optical image showing material flow
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Optical Micrographs of section1
A BC
D
E
Optical image location A
Fine and extended grains
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Optical Micrographs of section1
Optical Image location C
Direction of grain flow has oriented along bending direction (horizontal axis on this page) around
15-20°
No evidence of any cracks
within the macrostructure or
along the edges of the
section
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• Alpha case formation has been
investigated at three points, A, C and E,
of the 'L' shape section.
• Both optical microscope and SEM have
been used for alpha case evaluation.
No Alpha case formation
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Formability of Titanium Ti-6Al-4V sheets at low
temperature
• Introduction
• Warm Forming of Titanium 6Al-4V
• Initial lab results
• Production process validation
10/10/2019Confidential 33 MEMBER OF KOBE STEEL GROUP
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How does it work?
10/10/2019Confidential 34 MEMBER OF KOBE STEEL GROUP
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Quintus High Pressure Warm Forming – Step by step
10/10/2019Confidential 35 MEMBER OF KOBE STEEL GROUP
Click: https://www.youtube.com/watch?v=gcSyicC-tFk
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Next step
• Equipment / system validation
• Robustness
• Handling
• Productivity
• Process cost
• Isolation
• Process validation
10/10/2019Confidential 37 MEMBER OF KOBE STEEL GROUP
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HPWF system under installation
10/10/2019Confidential 38 MEMBER OF KOBE STEEL GROUP
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Next step - Partners welcome!
• Equipment / system validation
• Robustness
• Handling
• Productivity
• Process cost
• Isolation
• Process validation
• Tooling
• Demonstrators, full size
• Spring back compensation
• Simulation correlation
• Final stress relief requirements
• Process envelope / part suitability
• Market acceptance
10/10/2019Confidential 39 MEMBER OF KOBE STEEL GROUP
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Formability of Titanium Ti-6Al-4V sheets at low
temperature
• Introduction
• Warm Forming of Titanium 6Al-4V
• Initial lab results
• Production process validation
10/10/2019Confidential 40 MEMBER OF KOBE STEEL GROUP
Thank you for your attention!
Sture Olsson
Björn Carlsson
Mikael Bergkvist
https://quintustechnologies.com/
