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High speed forming, a smart way to manufacture complex parts with high performance alloys

Thursday (09.11.2017)
10:55 - 11:15
Part of:

Nowadays transportation industry is looking for weight saving in order to reduce emissions. Advanced aluminium and titanium alloys are being developed to meet demanding objectives. Nevertheless, the high mechanical properties of such alloys are usually associated to a low ductility, which does not allow a straightforward manufacturing route for complex parts. Multiple intermediate heat treatments or hot forming processes often have to be considered but are rather expensive.

High speed forming is an elegant alternative and economical way to manufacture complex parts. . Under high speed, the deformation of the material is essentially viscoplastic in an adiabatic mode. Therefore, high speed deformation brings some advantages over conventional forming processes such as a much improved formability and some limited springback. This allows creating complex shapes and details, even with less formable alloys.

High energy hydroforming (aka explosive forming) and electro hydroforming are currently being applied to complex aerospace parts made of strong age-hardening aluminium alloys in several research projects. In the recent years, numerical modelling and industrial process development have made such technologies suitable for serial production. The high energy hydroforming and the electro hydroforming of some illustrative aerospace parts developed in the above mentioned transportation and aerospace R&D projects will be presented, emphasizing the numerous advantages of such forming methods over conventional mechanical forming processes. Microstructure and constitutive law under high speed solicitation will be detailed for some age-hardening aluminium alloys formed in final use temper. The interest of using numerical modeling as a predictive tool to support process development will be explained as well.

Additional Authors:
  • Marcel Oud
    3D Metal Forming


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