Investigation of the complexities inherent in manufacturing near-unconstrained superplastic parts by experiments and simulation

Abstract. Superplastic forming is a sheet metal process that has found widespread use in the aerospace industry. It produces parts are free of residual stresses, dimensionally accurate, and with strains unobtainable using conventional methods. When combined diffusion bonding, phenomena where under similar processing conditions material involved will produce near flawless weld itself, variety reinforcements internal structures can be produced. In most superplastic blow formed up to die takes on dimensions small variations thicknesses. this work, however, we investigate unique bonding four sheets. The two outer sheets while inner form complex sandwich structure. These completely unsupported except at edges part. Superplasticity stress-history dependent somewhat chaotic nature. Therefore, have large variance geometry due fact they only limited constraints shift translate as operation progresses. Without rigid magnified create changes final geometry. variances quantified techniques measure major features including cell wall measurements, gas pathway computer vision-based analysis. Two- three-dimensional finite element simulations were used compare characterization results idealized analysis provide insights into complexities manufacturing such structures.