Titanium alloys, due to their excellent strength, corrosion resistance, and biocompatibility, are widely used in aerospace, medical, marine engineering, and other fields. However, the forming process is complex, requiring the selection of the appropriate forming method based on the part's shape, size, and performance requirements.
This article will provide a detailed introduction to the seven major titanium alloy forming processes, including bending, stamping, spinning, injection molding, hot isostatic pressing, dieless multi-point forming, and drawing technology, analyzing their process characteristics and application areas.
1. Bending
Content: Shape control is achieved through a combination of plastic deformation and elastic recovery. Springback compensation (allowing a 2°-5° margin) is required. The minimum bend radius is typically three times the pipe diameter for cold bending or two times for hot bending. Hot bending temperatures are controlled between 177°C and 427°C, and inert gas shielding is used to prevent oxidation.
Applications: Pressure hulls for deep-sea probes and pipelines for chemical equipment.
Features: Stress relief annealing is required after cold bending, the springback angle after hot bending can be controlled within 1°, and the surface oxide layer thickness is <0.1mm.
2. Stamping
Technology: Cold stamping (wall thickness <2mm) and hot stamping (deformation >50%) are used to achieve complex shapes through temperature control. Hot stamping prioritizes heating the blank to 600-800°C and preheating the mold to 150-200°C to reduce thermal stress.
Applications: Aircraft wing panels, chemical equipment heads.
Features: Final annealing is required after cold stamping to relieve stress. High-temperature hot stamping can achieve a single deformation of 60% and a surface roughness Ra <0.8μm.
3. Spinning
Technology: A spinning tool applies pressure to a rotating blank to form a hollow, revolved part. This process is divided into standard spinning (constant wall thickness) and high-pressure spinning (variable wall thickness). The spinner feed rate and mandrel speed are the key parameters.
Applications: Space rocket fuel tank bottoms, aircraft engine nozzles.
Features: Material utilization exceeds 90%, and tolerances for thin-walled titanium alloy parts can be controlled within 0.03-0.05mm.
4. Injection Molding
Description: This titanium alloy forming processes involves mixing titanium alloy powder with a binder and then injection molding. Debinding and sintering are then performed to produce precision parts. Powder particle size distribution and oxygen content must be controlled.
Applications: Dental implants, surgical instruments.
Features: Excellent biocompatibility, suitable for small, complex structural parts, and high dimensional accuracy.
5. Hot Isostatic Pressing
Description: Full densification of titanium alloy powder or billet under high temperature and pressure, with pressures reaching over 100 MPa and temperatures ranging from 900-1200°C.
Applications: High-temperature aircraft engine components, nuclear power equipment.
Features: Eliminates internal porosity, improves material mechanical properties, and is suitable for components requiring high reliability.
6. Dieless Multi-Point Forming
Description: Uses a multi-point matrix die to locally plastically deform titanium sheets to achieve large curved surfaces. The displacement of each point must be controlled to coordinate the deformation.
Applications: Ship pressure hulls, spacecraft shells.
Features: Eliminates the need for traditional die sets, making it suitable for single-piece or small-batch production and reducing manufacturing costs.
7. Stretching Technology
Description: Applying axial tension and lateral pressure to titanium sheets to achieve double-curvature forming. The ratio of tensile force to blank-holding force must be controlled to avoid cracking.
Applications: Spacecraft skins, automotive panels.
Features: High forming precision, excellent surface quality, and suitable for parts with complex shapes and high curvature.
As the application of titanium alloys continues to expand, titanium alloy forming processes are also undergoing continuous innovation and development. In the future, with the continuous emergence of new materials and processes, titanium alloy forming technology will become more efficient, precise, and environmentally friendly, providing strong support for the development of high-end manufacturing.
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