Simulating Superplastic forming

BAE Systems' engineers developed modeling tools and techniques to optimize superplastic forming of titanium structures.

Superplastic forming and diffusion bonding of titanium structures provides the capability to design and manufacture complex aerospace structures as single items. These unitized structures would otherwise have to be fabricated from a large number of components. Typical aerospace applications include jet aircraft control surfaces that require efficient, high-strength and stiffness structures, which may be formed using integral X-core or Warren girder stiffeners.

Successful forming depends upon good design, process control, and understanding of the forming process. In particular it is necessary to form parts at an appropriate strain rate. This is controlled by a pressure time cycle (PTC), which for simple low-strain components can be derived by iteration. Process simulation by finite-element analysis is required for more complex components.