MATERIALS, PROCESSES & FINISHES The hybrid SPF process could slash forming times by 50%
FORMING NEW OPPORTUNITIES
How a new hybrid approach to titanium manufacturing is boosting UK aerospace opportunities
S
uperplastic forming (SPF) is a near net shape manufacturing method for producing thin- sheet metallic components,
and is typically used to create complex-shaped titanium parts used within the aerospace sector. Now, a new hybrid approach to the manufacturing process is poised to boost capability in the UK market and increase manufacturing efficiency for key aerospace components. The project forms part of the
National Aerospace technology Exploitation Programme (NATEP), and is led by Shropshire-based lightweight
engineering firm SDE Technology. Supported by the Advanced Forming Research Centre (AFRC) within the National Manufacturing Institute Scotland (NMIS) Group and industry collaborators Boeing and Timet UK, SDE Technology is leading the development of a new hybrid SPF process that makes use of innovative new tooling to enable a significantly reduced process time.
A HYBRID APPROACH SPF is a specialised manufacturing technique used to mould highly ductile metals, such as aluminium, titanium
and certain steel alloys, into complex shapes by exploiting their superplastic behaviour. “In this process, a metal sheet is
heated to a high temperature where it becomes extremely malleable, typically between 40-70% of its melting point,” explains Les Gill, member of SDE’s Technical Advisory Group and principal consultant at TaBA Associates. “The softened metal is then placed into or over a mould and shaped using controlled, pressurised gas to stretch and form it to the desired contours. Once formed, the metal is cooled under
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