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Superplastic forming of advanced metallic materials: Methods and applications

Edited by G Giuliano, University of Cassino, Italy

Woodhead Publishing Series in Metals and Surface Engineering No. 44

 - reviews types of superplastic metals and standards for superplastic forming
 - discusses the modelling of superplastic forming, including mathematical and finite element modelling
 - examines various applications, including superplastic forming of titanium, aluminiun and magnesium alloys
 - provides an invaluable reference for aerospace and automotive engineers and metallurgists

Ultra fine-grained metals can show exceptional ductility, known as superplasticity, during sheet forming. The higher ductility of superplastic metals makes it possible to form large and complex components in a single operation without joints or rivets. The result is less waste, lower weight and manufacturing costs, high precision and lack of residual stress associated with welding which makes components ideal for aerospace, automotive and other applications. Superplastic forming of advanced metallic materials summarises key recent research on this important process.

Part one reviews types of superplastic metals, standards for superplastic forming, processes and equipment. Part two discusses ways of modelling superplastic forming processes whilst the final part of the book considers applications, including superplastic forming of titanium, aluminium and magnesium alloys.

With its distinguished editor and international team of contributors, Superplastic forming of advanced metallic materials is a valuable reference for metallurgists and engineers in such sectors as aerospace and automotive engineering.

Note: The Publishers wish to point out an error in the authorship of Chapter 3 which was originally listed as: G. Bernhart, Clément Ader Institute, France. The correct authorship is: G Bernhart, P. Lours, T. Cutard, V. Velay, Ecole des Mines Albi, France and F. Nazaret, Aurock, France. The Publishers apologise to the authors for this error.

ISBN 1 84569 753 7
ISBN-13: 978 1 84569 753 2
June 2011
384 pages  234 x 156mm  hardback  
£135.00 / US$230.00 / €160.00

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About the editor

Gillo Giuliano works in the Department of Mechanics, Structures and Environment at the University of Cassino, Italy. Professor Giuliano is internationally-known for his work on superplasticity.

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Contents

PART 1 SUPERPLASTIC FORMING METHODS
PART 2 MODELLING OF SUPERPLASTIC FORMING
PART 3 APPLICATIONS OF SUPERPLASTIC FORMING

PART 1 SUPERPLASTIC FORMING METHODS

Metals for superplastic forming
N Ridley, University of Manchester, UK
 - Introduction
 - Historical aspects of superplasticity
 - Types of superplastic materials
 - Grain refinement
 - Processing of commercially significant alloys to develop SP microstructures
 - High strain rate superplasticity
 - Grain refinement by severe plastic deformation (SPD)
 - Mechanisms of superplasticity
 - Sources of further information and advice
 - References

Standards for superplastic forming of metals
F Abu-Farha, Penn State Erie, USA and R Curtis, King’s College London, UK
 - Introduction
 - Need for standards
 - Existing standards
 - Issues with existing standards
 - Towards improved standards
 - References

Processes and equipment for superplastic forming of metals
G Bernhart, P Lours, T Cutard, V Velay, Ecole des Mines Albi and F Nazaret, Aurock, France
 - Introduction
 - Superplastic forming processes
 - Forming equipment
 - Forming dies
 - Conclusion
 - References

High-temperature lubricants for superplastic forming of metals
P A Friedman and S G Luckey, Ford Research and Advanced Engineering
 - Introduction
 - Lubrication mechanisms
 - SPF lubricants
 - Influence of friction and lubricant on forming
 - Testing and evaluation of lubricants
 - Production issues
 - Conclusions
 - References

The use of laser surface modification in combined superplastic forming and diffusion bonding of metals
G Q Wu and G X Luo, Beijing University of Aeronautics and Astronautics (BUAA), China
 - Introduction
 - Effect of laser surface modification on alloy surface
 - Diffusion bonding of laser surface modified alloys
 - Simulation of bonding process
 - Conclusion
 - References
 - Appendix: list of symbols

PART 2 MODELLING OF SUPERPLASTIC FORMING

Mathematical modelling of superplastic metal sheet forming processes
G Giuliano, University of Cassino, Italy
 - Introduction
 - Membrane theory
 - Flow rule
 - Analysis of superplastic free forming processes
 - Material constants from bulging tests
 - References

Finite element modelling of thin metal sheet forming
J Bonet and A J Gil, Swansea University, UK
 - Introduction
 - Continuum model
 - Finite element formulation and time integration schemes
 - The incremental flow formulation
 - Pressure cycle algorithms
 - Die representation and contact algorithms
 - Commercial codes
 - Applications
 - Future trends
 - References

Constitutive equations for modelling superplastic forming of metals
J Lin and T Zhu, Imperial College London, UK and L Zhan, Central South University, P. R. China
 - Introduction
 - Constitutive equations for superplastic alloys
 - Determination of constitutive equations from experimental data
 - Case study: simulation of superplastic forming
 - Conclusions
 - References

Predicting instability in superplastic forming of metals
S B Leen, NUI Galway, Ireland
 - Introduction
 - Theoretical considerations
 - Forming analyses and experiments
 - Results and discussion
 - Conclusions and future trends
 - References

PART 3 APPLICATIONS OF SUPERPLASTIC FORMING

Superplastic forming and diffusion bonding of titanium alloys
M Jackson, University of Sheffield, UK
 - Introduction
 - Titanium alloys
 - The superplastic forming/diffusion bonding (SPF/DB) process
 - Applications
 - Sources of further information and advice
 - Acknowledgements
 - References

Superplastic forming of aluminium alloys
R Grimes, University of Warwick, UK
 - Introduction
 - History
 - Superplastic aluminium alloys
 - Cavitation in superplastic aluminium alloys
 - High strain rate superplasticity
 - Exploitation of superplastic aluminium alloys
 - References

Quick plastic forming of aluminium alloys
P E Krajewski and J G Schroth, General Motors, USA
 - Introduction
 - QPF process overview
 - Hot forming systems – prior deficiencies and new concepts
 - Integrally heated tool system
 - Tool heating system
 - Temperature distribution in a decklid inner panel tool
 - Ancillary benefits of integrally heated tools
 - Production validation experience
 - Material development
 - Lubrication
 - Conclusions
 - References

Superplastic forming of magnesium alloys
R Grimes, University of Warwick, UK
 - Introduction
 - History
 - Properties of magnesium
 - Superplasticity in magnesium alloys
 - Manufacture of superplastic magnesium alloy sheet
 - Superplastic forming of magnesium components
 - References

Superplastic microtubes fabricated by dieless drawing processes
T Furushima and K Manabe, Tokyo Metropolitan University, Japan
 - Introduction
 - Industrial application of microtubes
 - Fundamentals of dieless drawing process
 - Superplastic dieless drawing process
 - FE simulation of superplastic dieless drawing process
 - Grain refinement process of metal tubes for superplastic dieless drawing process
 - Other applications
 - Conclusion
 - References