The superplastic forming/diffusion bonding of TA7 titanium alloy for manufacturing hollow structure with stiffeners

Du, Zhihao; Wang, Chunxu; Liu, Qing; Wang, Shan; Liu, Yang; Wang, Guofeng

doi:10.1016/j.jmapro.2021.10.064

Cited by 17 publications

(5 citation statements)

References 27 publications

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“…Among them, the four-layer structure is applied in aircraft wings and rudders [6] due to high overall stiffness and bearing capacity. Ti-alloy sandwich structures are fabricated by stamping and brazing [7], additive manufacture [8], superplastic forming and diffusion bonding (SPF/DB) technology [9]. Compared with the other technology, the SPF/DB process can fabricate large-scale overall complex structures and has the advantages of high forming efficiency and designability.…”

Section: Introductionmentioning

confidence: 99%

A constitutive model based on internal variable method for the microstructure simulation of four-layer structure formed by the superplastic forming/diffusion bonding process

Wu¹,

Fan³

et al. 2023

Preprint

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This study set out to realize the prediction of microstructure evolution and mechanical properties of the titanium alloy four-layer structure formed by the superplastic forming/diffusion bonding (SPF/DB) process. The flow behavior and the microstructure evolution of TC31 alloy were studied by the high-temperature experiments. A physically-based constitutive model was established and applied in the superplastic forming process of the four-layer structure. The TC31 titanium alloy four-layer structure was fabricated to verify the accuracy of the constitutive model. The results showed that the main reason for the increase in material stress and the decrease in elongation was the growth of grains. The TC31 four-layer structure was soundly fabricated by SPF/DB process, and the maximum damage value of the structure was located at the sidewall area with a value of 0.16. The compression strength of the structure was 19.0MPa, and the compression failure mode of the four-layer structure was the cracking of the bonding area. The experimental results were similar to the simulation results, which demonstrated that the finite element simulation with the internal variable model could accurately predict the shape, the thickness distribution and the damage distribution of the four-layer structure during the SPF process.

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Section: Introductionmentioning

confidence: 99%

A constitutive model based on internal variable method for the microstructure simulation of four-layer structure formed by the superplastic forming/diffusion bonding process

Wu¹,

Fan³

et al. 2023

Preprint

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show abstract

“…9 SPF/DB process is considered an efficient and advanced manufacturing technology, and it can fabricate large-size overall structures with high design freedom. 10,11 Tan et al 12 fabricated Ti6Al4V sandwich structure with a strong joint by SPF/DB process, and improved the shear property of this structure. Li et al 13 manufactured different titanium alloy topological structures by designing the shape of core sheets and analyzed the compression, shear, bending and torsion properties by the FE model and test.…”

Section: Introductionmentioning

confidence: 99%

Structural optimization and experimental study on the Ti-alloy Kagome structure formed by the superplastic forming/diffusion bonding process

Wu,

Chen

et al. 2023

Jnl of Sandwich Structures & Materials

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The structural optimization of Ti-alloy lattice structure formed by the superplastic forming/diffusion bonding (SPF/DB) process is a high-nonlinear problem with multiple design variables. The problem is solved in this research by introducing the modified Kriging response surface model based on structural mechanics analysis and the genetic algorithm into the optimization design of the Kagome structure. The comprehensive influence of the structural parameters on the shape and compressive strength of the structure is analyzed, and the optimized structural parameters are obtained. The SPF/DB forming and performance test of the optimized Kagome structure are carried out for verifying the accuracy of the model. The results show that the modified Kriging response surface model of the Kagome structure performs well in describing the relationships between the structural parameters and the simulation results, the average relative error of the predicted groove depth and compression strength are 2.4% and 4.5%, respectively. The specific compression strength and the specific compression modulus of the optimized Kagome structure are [Formula: see text] and [Formula: see text]. Based on the compression strength results calculated by the Kriging model, a new Ashby plot for the compressive strength as function of density is obtained.

show abstract

Section: Introductionmentioning

confidence: 99%

“…Through the bending process instead of SPF, a more flexible shape can be achieved. Although previous studies adopted a bending process with DB to manufacture titanium alloys such as Ti22Al25Nb, each process was applied sequentially [33][34][35]. Although using SPF to generate pressure has several advantages, building equipment using this method is difficult, and forming specific shapes requires additional processes.…”

Section: Introductionmentioning

confidence: 99%

One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets

et al. 2023

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A one-step hybrid bending/diffusion bonding process (HB/DBP) was developed for application to Ti-6Al-4V sheets to effectively improve buy-to-fly (BTF) ratio of aircraft parts, integrating sequential diffusion bonding followed by a bending process. The resulting bonding characteristics of these titanium alloy sheets were analyzed. Microstructural analysis and mechanical lap shear tests were performed to estimate the bonding quality. Additionally, bonding ratio, thickness strain, and shear strength were evaluated in relation to pressure under increasing temperature. When the applied pressure was lower than 0.5 MPa, early failure occurred at the joint of the specimens. However, when high pressure was applied, early failure occurred near the joint. To discuss the phenomenon, time-dependent viscoplastic material properties were characterized, and a numerical simulation analysis was performed. Viscoplastic deformation was observed around the bending area, which caused weakness around the bond under high-pressure conditions. A prototype of a Y-shaped heat shield was manufactured and the buy-to-fly ratio was effectively improved using the newly developed process. This study demonstrates the potential of applying the developed process for producing aircraft parts and the importance of viscoplastic behavior for the analysis of final product reliability.

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The superplastic forming/diffusion bonding of TA7 titanium alloy for manufacturing hollow structure with stiffeners

Cited by 17 publications

References 27 publications

A constitutive model based on internal variable method for the microstructure simulation of four-layer structure formed by the superplastic forming/diffusion bonding process

A constitutive model based on internal variable method for the microstructure simulation of four-layer structure formed by the superplastic forming/diffusion bonding process

Structural optimization and experimental study on the Ti-alloy Kagome structure formed by the superplastic forming/diffusion bonding process

One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets

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