Construction of next-generation superplastic forming using additive manufacturing and numerical techniques

Abstract

The superplastic forming process is used in a wide range of high-value-added manufacturing sectors to make lightweight, complex-shaped components for high-performance applications. Currently, it is a high-cost process, for example, the superplastic forming of titanium alloys involves a high-temperature furnace, costly (mould) tooling and has a high utilization of resources such as argon gas and energy. The authors of this article propose a prototype for next-generation superplastic forming laboratory equipment. The aim is to develop improved methods, particularly for heat management in the superplastic forming process, to allow a more widespread application of the process to manufacture lower cost products. The next-generation superplastic forming tool comprises a tool in the form of a hemispherical shell, pressure chamber with incorporated water cooling system and an infrared heating system. The construction, usability and suitability of the next-generation superplastic forming equipment have been proven by a series of physical experiments, and numerical simulations are performed and the results are presented and discussed in this article.