Overview of Superplastic Forming Research at Ford Motor Company

Friedman, Peter A.; Luckey, S. George; Copple, W. B.; Allor, R. L.; Miller, Carlin J.; Young, C.

doi:10.1361/10599490421277

Cited by 32 publications

(16 citation statements)

References 5 publications

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“…In a study on the production of aluminum door structures, Luckey et al (2007) find tool savings of 80% for SPF compared to drawing. Friedman et al (2004) also compare SPF (in this case of aluminum car hoods) to drawing, finding that SPF is cheaper for batch sizes smaller than 5,000 parts. Despite the apparent cost savings associated with FCF and SPF in the above studies, it is unclear whether these savings correspond to energy savings or a reduction in environmental impacts.…”

Section: Die-set and Sheet Metal Impactsmentioning

confidence: 99%

“…The periphery of the formed part must be trimmed in order to make the final part shape. The blanks are made from specific superplastic alloys with a fine grain structure (<10 m) that allows very high strains to be developed at the elevated forming temperatures (Langdon, 2013); a single superplastic forming process can often substitute multiple drawing (and annealing) processes needed to form a complex geometry (Friedman et al, 2004). SPF was developed to exploit this high formability; it was commercialized for military aircraft in the 1980s and expanded to commercial aircraft and other applications in the 1990s (Sanders, 2004).…”

Section: Introductionmentioning

confidence: 99%

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The energy requirements and environmental impacts of sheet metal forming: An analysis of five forming processes

Cooper

Rossie

Gutowski

2017

Journal of Materials Processing Technology

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Industrial emissions must be dramatically reduced to avoid the potentially dangerous effects of climate change. In order to contribute to the necessary cuts, this article focuses on the energy and material efficiency of sheet metal forming. The processes considered include traditional methods, such as drawing and stretch forming, and newer technologies developed in recent decades such as hydroforming (fluid cell forming), superplastic forming, and incremental sheet forming. In this analysis, we conduct case studies on forming processes at leading US car and aerospace manufacturers. The case studies include electrical power measurements on the forming machines and also consider the impacts of making the dies, sheet metal, and lubricant. Cradle-to-gate energy demands and environmental impacts are modeled in SimaPro using data based on ecoinvent 3.1 database values. The results show that idling consumes significant electricity; however, other than for incremental forming, the impacts of press electricity are small compared to the impacts of making the sheet metal. The case studies inform generalized models for each process that allow per part impacts to be estimated based only on final part material, size (surface area, thickness,

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Section: Die-set and Sheet Metal Impactsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

The energy requirements and environmental impacts of sheet metal forming: An analysis of five forming processes

Cooper

Rossie

Gutowski

2017

Journal of Materials Processing Technology

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“…A trend towards forming at elevated temperatures as well as temperature assisted forming technologies can be observed. Using sheet metal forming procedures such as warm forming [2,3,4], hot forming [5,6] and superplastic forming [7] more complex sheet metal aluminium parts can be produced. However, high temperature forming methods can result in excessive thinning and necking; and a reduction in strength through the mechanism of recovery, recrystallization and precipitation.…”

Section: Introductionmentioning

confidence: 99%

Improved Formability of AA5182 Aluminium Alloy Sheet at Cryogenic Temperatures

Sotirov

Falkinger

Grabner

et al. 2015

Materials Today: Proceedings

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This study describes the forming behaviour of work hardening AA5182 sheet alloy at various low temperatures. The material parameters including flow curves, Lankford parameters and forming limit curves were obtained by experimental testing in the temperature range from room temperature to -196 °C, which were then used for isothermal forming simulations using the finite element method (FEM). It was found that strength, elongation and forming limits increase with decreasing temperature. The finite element model was validated using deformed Nakajima strips. Numerical results presented in this study demonstrate the potential of cryogenic forming for manufacturing of complex automotive components.

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“…were carried out (Novotny and Geiger, 2003;Friedman et al, 2004). Warm forming of aluminum alloy panels is usually carried out in the temperature range of 200-350 • C. Effects of temperature and strain rate on the formability of aluminum alloy were mainly investigated by uniaxial tensile, biaxial tensile, stretch and drawing test in the previous researches Ghosh, 2003, 2004;Naka and Yoshida, 1999;Naka et al, 2003Naka et al, , 2001Blot et al, 2001;Ohwue et al, 2002).…”

Section: Introductionmentioning

confidence: 99%

Formability of 6k21-T4 car panel sheet for viscoelastic–plastic flexible-die forming

Wang

2008

Journal of Materials Processing Technology

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Overview of Superplastic Forming Research at Ford Motor Company

Cited by 32 publications

References 5 publications

The energy requirements and environmental impacts of sheet metal forming: An analysis of five forming processes

The energy requirements and environmental impacts of sheet metal forming: An analysis of five forming processes

Improved Formability of AA5182 Aluminium Alloy Sheet at Cryogenic Temperatures

Formability of 6k21-T4 car panel sheet for viscoelastic–plastic flexible-die forming

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