1. Advanced Forming Processes
Super plastic Forming

2. 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

4. SUPERPLASTIC FORMING DEFINITION
A process for shaping super-plastic materials, a unique class of crystalline materials that exhibit exceptionally high ductility with neck-free 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.

5. 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.

7. Video 1

8. 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.

9. Types of forming superplastic sheet materials:
• Blow/vacuum forming • Thermo-forming • Deep drawing • Superplastic forming/diffusion bonding (SPF/DB)

10. Production Process: SPF
Need presses 1000, 3000and 8000kN
SPF/HGPF allows complex shape design with Hi-strength alloys

11. SPF is a Gas pressure forming process(HGPF)

12. Typical SPF/ HGPF-Sample Geometries
Magnesium ~ AZ 31, MA 2-1, etc.
Aluminium ~ AA 5083, 7475, etc.
Titanium ~Ti 6-4, BT6, BT6-S, Ti ,
β 21 S, SP 700, Ti , Ti-MMC
Ti-Al ~ gamma TiAl
Steel ~ , Lean duplex, etc.
Nickel ~ IN 718

13. APPLICATIONS

14. Aerospace - Lightweight Laminar Structures
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

15. 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

16. 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

17. Architectural Cladding, Bullnose, Ceiling and Acoustic Panels
Example of decorative panels
Roof panels of the Charléty stadium in Paris

18. Additional sectors of application
Application in sports
Application in arts
Application in furniture

20. Medical

21. Tools for SPF forming Example of non metallic tool for SPF
Lid of metallic container for SPF

22. Production Process: Diffusion Bonding

24. DB of Plates;e.g. Heat Exchangers

25. SPF/DB* Sandwich Design

26. SPF/DB Sandwich Design

27. Vessel manufacturing

28. ADVANTAGES Complex shapes are easily made Flexibility in design.
Low applied stress for forming HSLA materials.
Low capital cost on equipments.
Effective material utilization and savings.

29. DISADVANTAGES
Inferior creep resistance
Very slow process.

30. Thank You