Series Parts Manufacturing by Infrared Superplastic Forming With Numerical Techniques for Thermal Regulation

Abstract

Materials used for Superplastic forming (SPF) are mainly titanium alloys which are good candidates to produce lightweight complex-shaped components for high performance aerospace applications. SPF process has limitations because it involves a high-temperature furnace with poor heat efficiency and expensive tooling with low management flexibility. Enhancing this manufacturing process is a major challenge for the aerospace industry which is facing to important production ramp-up and cost reductions. Direct heating combined with tool heat management result in significant savings of SPF process: production time savings by drastically reduce the heating time, reduction of maintenance costs and energy savings by significant heat efficiency improvement. Aurock developed direct heating by Infrared emitters and succeed in forming series 1.5x1m² Ti6Al-4V blanks. A key point with this new technology is to ensure a homogeneous blank temperature all along the forming. This point is achieved thanks to lamp power modulations and numerical techniques to secure the blank thermal regulation with a full radiative flux control at different forming stages. Results obtained are stable and repeatable regarding to dimensional criteria, post-forming thicknesses distribution and microstructure. Numerical predictions are in very good agreement with the experimental results, enabling robust machine setup for series Infrared SPF parts production.