Us5069383a diffusion bonding and superplastic forming. Superplastic forming and diffusion bonding wikipedia. Superplastic forming and diffusion bonding technology spfdb of ti6al4v alloy has allowed the manufacturing of complex honeycombtype structures, saving total processing time and number of single parts. They still rely on the fundamental principle of heating the metal to increase its malleability. For superplastic forming, many steps of mechanical forming are reduced, with their corresponding time and cost savings. Journal of alloys and compounds materials science and. Diffusion bonding on superplasticaluminum and magnesium.
In the current model, the diffusion bonding processes consists of two stages. Utilizing the above two characteristics, an spfdb sandwich structure can be fabricated by diffusion bonding at least three superplastic alloy sheets at selected. Mar 01, 2000 applications of superplastic forming and diffusion bonding to hollow engine blades applications of superplastic forming and diffusion bonding to hollow engine blades xun, y. Diffusion bonding may be used, with superplastic forming, to create a great range of cellular structured materials, with great potential for material efficiency, multifunctionality and lightweighting. Method for superplastic forming of metals with concurrent. Applications of superplastic forming and diffusion bonding. Super plastic forming and diffusion bonding presses operate similarly to hot forming presses with a few important distinctions. The research at the langley research center larc of nasa has taken a different approach where superplastic forming was combined with weldbrazing to fabricate structural hardware.
Standard titanium alphabeta alloys, such as 6al4v, form at temperatures between 900 and 925c 16501700f. Db can be successfully developed together with superplastic forming spf as they share similar process parameters, although for spf the requirements are. Ti 6al 4v and some stainless steels this is around 900 c 1,650 f and for aluminium alloys e. No commercial applications have yet been found for the superplastic forming of materials by generating internal stress.
Breakthrough technologies in aerospace industry for. Sound surface layers with identical or similar microstructures and properties are gained at the intended bonding surfaces. Why is diffusion bonding, when combined with the superplastic forming of sheet metals, an attractive fabrication process. Thus at boeing, spf is now considered as a baseline design option for many large assemblies dan sanders, 2000. It is not a brand new technique spfdb was developed through the 1990s and 2000s.
Concurrent solid state diffusion bonding and superplastic. Superplastic forming spf and diffusion bonding db of titanium may be a practical alternative to other types of high temperature materials for certain parts, as the material size limitation of titanium sheet is no longer a significant factor because of the new capabilities of joining sheets together using friction stir welding fsw 1 2 3. Forge nxt addresses regular superplastic forming as well was superplastic forming combined with diffusion bonding. Applications of superplastic forming and diffusion bonding to. Applications of superplastic forming and diffusion bonding to hollow engine blades applications of superplastic forming and diffusion bonding to hollow engine blades xun, y. Nov 14, 2006 combined superplastic forming diffusion bonding spfdb is an established technique for making structural components, particularly lightweight components requiring complex internal structures, from materials that exhibit superplastic properties at elevated temperatures. A process is described whereby an article is formed by a superplastic formingdiffusion bonding a stack of sheets 1 made in particular from an aluminiumlithium alloy. Examination of superplastic forming combined with diffusion bonding for titanium. Spf db super plastic forming diffusion bonding hot presses.
Superplastic forming and diffusion bonding spfdb is a technique allowing to manufacture complexshaped hollow metallic parts. Superplastic forming spf combined with diffusion bonding db has been used successfully for the fabrication of titanium aerospace hardware. Concordia university mse 521 lecture 1414 superplastic forming with diffusion bonding. The material is first heated up to promote superplasticity. Pdf this paper summarized recent progress in metal superplasticity and the application of. Emphasis has been placed on the metallurgy of superplastic flow in two phase titanium alloys, the microstructural and external factors which influence this behaviour. Superplastic forming and diffusion bonding cyberleninka. Superplastic forming and diffusion bonding process bae. Diffusion bonding an overview sciencedirect topics. Isostatic diffusion bonding of superplastic ti6al4v and. Superplastic formingdiffusion bonding spfdb is a technology that uses. Superplastic forming of advanced metallic materials. Based on the behaviour of the superplastic deformation of metallic glasses and pillings model, a diffusion bonding model suitable for metallic glasses is proposed in the present study. Jun 22, 20 combination of spf and db singlesheet multisheettwo sheetthreesheetfour sheettypes of spfdb process.
Till date lot of work has been done with similar type of titanium. In one embodiment, prior to diffusion bonding, the stack of alloy sheets and lamellar material may be sealed under vacuum. Combination of superplastic forming and diffusion bonding 6 pages, 6 figures basic level prepared by k. Shirzadi kings college cambridge a thesis submitted for the degree of doctor of philosophy at the university of cambridge december 1997.
After that, diffusion bonding due to high pressure and. In a superplastic forming diffusion bonding process, in particular for aluminumlithium alloys, the stopoff material in the diffusion bonding step is a porous lamellar material such as glass cloth or vermiculite paper. Many of these applications have been for military aircraft, whereby a complex builtup structure has been replaced with monolithic parts. Since titanium is also diffusion bonded to achieve excellent bond strength, this technology, by itself, and in combination with superplastic forming, provides. Combining superplastic forming diffusion bonding spfdb with laser surface modification remelting and cladding, provides a new approach to joining similar and dissimilar hightemperature metal materials. Superplastic forming involves stretching the material at least 200% beyond its original size, although the. Superplastic forming is a specialist process used for deforming metal sheet to extremely large plastic strains to produce thinwalled components to the nearnet shape. Thus, coupling of diffusion bonding with superplastic forming is considered a technology advancement since it will transform the manufacturing into a costeffective, and material and energ yefficient process. Spfdb superplastic forming and diffusion bonding presses. Super plastic forming requires exceptional amounts of heat for the metal to reach its super plastic state. The constant forming temperature was changed from 500 uc to. Such a strain rate would allow the forming of relatively complex structures in less than three minutes, including setup time.
Preliminary study of improving the speed and cost of. Superplastic forming an overview sciencedirect topics. Superplastic forming article about superplastic forming by. Superplastic forming spf is often combined with the diffusion bonding db in the manufacture. Preliminary study of improving the speed and cost of diffusion bonding of metal sheets show all authors. Titanium and titanium alloys superplastic forming of. The ability of materials to exhibit extensive plastic deformation generally the elongation is over 200% at an elevated temperature t 0. Ep0399772a2 diffusion bonding and superplastic forming. The use of laser surface modification in combined superplastic forming and diffusion bonding of metals. Concordia universitymech 4216511 lecture 1019 superplastic forming with diffusion bonding superplastic forming can be combined with diffusion bonding to produce a number of complex spfdb structures. Combination of superplastic forming and diffusion bonding.
Superplastic forming and diffusion bonding of titanium alloys. Examination of superplastic forming combined with diffusion. Roll diffusion bonding is an example of such a process. Combined superplastic forming diffusion bonding spfdb is an established technique for making structural components, particularly lightweight components requiring complex internal structures, from materials that exhibit superplastic properties at. Diffusion bonding combined with superplastic blow forming is the most widely used process for ti6al. A study of low temperature diffusion bonding processing of ti6al. Friction stir welding, superplastic forming and diffusion bonding. Diffusion bonding db is a joining process achieved by the application of load at elevated temperatures. Using a combination of superplastic forming spf and diffusion bonding db, it is possible to fabricate hollow bodies with a sandwich construction, with. Metrology and microscopy analysis of multisheet packs. There are a number of commercial applications of superplastic forming and combined superplastic forming and diffusion bonding, including aerospace, architectural, and ground transportation uses. Two metal sheets are welded together at their edges, then heated within the confines of a. The procedure can result in both cost and weight savings compared with conventional forming techniques.
Introduction among the high strength materials of interest in the aerospace industry, titanium holds. A process is described whereby an article is formed by a superplastic forming diffusion bonding a stack of sheets 1 made in particular from an aluminiumlithium alloy. Animated illustration of the diffusion bonding process. Super plastic forming and diffusion bonding in aerospace industries 1. The concurrent application of spf and db spfdb has been recognized as a novel manufacturing technology that can result in both cost reduction and weight saving compared with the conventional manufacturing method. Stretching of the sheet during superplastic forming is much higher than with rolling and sheet forming. The complete monotub tek cultivation walkthrough the easiest way to grow mushrooms indoors. The winner was superplastic forming and diffusion bonding, a technique used in the aerospace and luxury automotive industry to create very light, very strong monolithic structures. In a superplastic formingdiffusion bonding process, in particular for aluminumlithium alloys, the stopoff material in the diffusion bonding step is a porous lamellar material such as glass cloth or vermiculite paper.
In the aerospace industry, diffusion bonding db combined with superplastic forming is widely adopted to produce near net shape of titanium alloy structural parts. Spfdb super plastic forming diffusion bonding hot press. In this process pressure is applied by a gaz in order to obtain the final geometry. It combines superplastic forming spf with a second element diffusion bonding to create the completed structures.
Pdf this paper reports on investigations of the solid state formability and weldability of ti6al4v titanium alloy sheet with. Several methods for applying the two and foursheet titanium spfdb processes have. Diffusion bonding db combined with superplastic forming spf is now a well established route for the production of complex structures from a3 titanium alloys. The resultant molecular bond offers a fully homogeneous joint, which, in many cases, is undetectable under microscopic examination. This leads to a significant reduction in cost and weight around 3050% of the formed part and finds. Superplastic forming and diffusion bonding spfdb have provided some of the lightest, strongest, corrosion resistant, elegant and complex structures ever produced.
However, the process, heattreating at 0 c with some bonding pressure which induces material degradation caused by microstructure changes, may prevent practical application. The superplastic forming and diffusion bonding spfdb of hydrogenated ti6al2. Since high interfacial pressure and plastic deformation at elevated temperatures are beneficial in promoting solid state bonding, the joining operation can sometimes be combined with hot working processes used to reduce the section of the material. Superplastic forming is an industrial process used for creating precise and complex components out of superplastic materials. The applying pressure with respect to temperature should be in arange of which metals still act as a superplastic material. Used for forming titanium as well as certain types of aluminum and stainless steel, the super plastic forming process requires high heat. However, in an ever increasingly cost conscience world, will the process flourish or. Despite the attractiveness of integrating the two processes, thus far, diffusion bonding and superplastic forming have been a. Erie press systems manufactures a number of machines dedicated to super plastic forming, both with and without diffusion bonding capabilities. The effects of hydrogen contents and diffusion temperature on weldingon ratio of spfdb and microstructure of interface and matrix in ti600 alloy were investigated by. A study of low temperature diffusion bonding processing of ti. Superplastic forming of advanced metallic materials 1st edition. Superplastic forming article about superplastic forming. Theoretical study on behaviour of superplastic forming.
Demonstration of singlesheet formingusing superplastic formingdie and sheet are maintained at thesame temperature within a heatingpress. Superplastic forming spf can be used to form titanium into nearnet, complex shapes without springback. Both the processes when combined with superplastic forming produce near net shape of parts and complex sheet structures with reduced weight and fabrication costs compared to mechanically fastened structures. Superplastic formingdiffusion bonding spfdb is a technology that uses material.
To get further details about forge capabilities on this process or to obtain a quote, please contact our team. May 10, 2011 animated illustration of the diffusion bonding process. Oct 08, 2012 the winner was superplastic forming and diffusion bonding, a technique used in the aerospace and luxury automotive industry to create very light, very strong monolithic structures. Pdf advanced superplastic forming and diffusion bonding of. During diffusion bonding, the kinetic of atomic diffusion is slow and is obtained by a microscopic viscoplastic deformation required to expel. However, and due to the just exposed cost reasons, spfdb applications are almost restricted to the aerospace industry 2. Advancements of superplastic forming and diffusion bonding. Super plastic forming and diffusion bonding in aerospace.
Several methods for applying the two and foursheet titanium spfdb processes have been devised, including the. Nov 18, 1975 the processes of superplastic forming of metals and diffusion bonding have individually been disclosed in the prior art. Materials science and technology journal of alloys and. Effect of hydrogen content on superplastic forming and. This property is used industrially to create hollow products, combining diffusion bonding and superplastic forming. The superplastic in the name is the forming of the structure by inflation using gas. Diffusion bonding combined with superplastic blow forming is the most widely used process for ti6al4v spf as it leads to the formation of a honeycomb structure which is otherwise not producible 29. Breakthrough technologies in aerospace industry for titanium. Diffusion bonding on superplasticaluminum and magnesium alloys. Superplastic forming and diffusion bonding solheim. Manufactured via superplastic forming to study possible diffusion bonding. The value of this paper is to summarize the main features, to explain the modeling chosen and to propose a new strategy for rheological characterization of materials by bulge test. The processes of superplastic forming of metals and diffusion bonding have individually been disclosed in the prior art. Kaibyshev 16 used superplastic forming and diffusion bonding spfdb technology to realize a sound joint of tial alloys.
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