Advanced Forming
Processes
Super plastic
Forming
• 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
SUPERPLASTIC FORMING
• DEFINITION
• A process for shaping super-plastic
materials, a unique class of
crystalline materials that exhibit
exceptionally high ductility with neckfree 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.
• 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.
Video 1
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.
• Types of forming
superplastic sheet materials:
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Blow/vacuum forming
Thermo-forming
Deep drawing
Superplastic forming/diffusion
bonding (SPF/DB)
Production Process: SPF
• Need presses
1000, 3000and
8000kN
• SPF/HGPF
allows complex
shape design
with Hi-strength
alloys
SPF is a Gas pressure
forming process(HGPF)
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, Ti6-24-2,
4. β 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
APPLICATIONS
Aerospace - Lightweight
Laminar Structures
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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
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
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
Architectural Cladding, Bullnose, Ceiling and
Acoustic Panels
Roof panels of the Charléty stadium in Paris
Example of decorative panels
Additional sectors of application
Application in sports
Application in arts
Application in furniture
Medical
Tools for SPF forming
Example of non metallic tool for SPF
Lid of metallic container for SPF
Production Process:
Diffusion Bonding
DB of Plates;e.g. Heat Exchangers
SPF/DB* Sandwich Design
SPF/DB Sandwich Design
Vessel manufacturing
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.
DISADVANTAGES
1. Inferior creep resistance
2. Very slow process.