Optimization of hot gas pressure forming process for titanium alloy component

In this paper, hot gas pressure forming (HGPF) of titanium alloy irregularly profiled tubular component using laser-welded tube was studied by both simulation and experiment. Uniaxial tensile tests of base metal (BM) under different conditions were performed to determine the true stress–strain curves. The forming process was optimized by finite element simulation and response surface method (RSM). Results show that the forming pressure increases with the decreasing temperature and increasing strain rate. Microstructures of BM are sensitive of forming temperature, strain and strain rate. Wrinkling and local thinning of the component can be avoided by a reasonable initial tube diameter during the forming. Ideal weld position should be determined to avoid the failure of the weld seam (WS). A qualified TC2 titanium alloy component with both high dimensional accuracy and good post-form properties was successfully formed by HGPF using the optimized forming parameters. The total heating and forming time of the tube was less than 30 min. Both of the post-form properties and microstructures of the component were almost the same with the initial material.