Superplastic Forming (SPF) of Complex Sheet Metal Parts and Structures

Superplastic forming(SPF) has been developed as an advanced forming process for making the complicated and large parts and structures, such as vehicle and aeroplane components, which are difficult to be made by then traditional forming process. In this chapter, the principles and conditions of SPF are firstly introduced and then the advantages and disadvantages of SPF are discussed. The common superplastic materials such as titanium, aluminum, and magnesium alloys are also briefly introduced for making different superplastic formed parts. To explore and establish a physical insight into the essence of SPF process, the finite element simulation of SPF and quality control method for SPF process are also presented. In addition, the structure design and material selection of SPF die are delineated. Finally, by taking the SPF of industrial AA5083 aluminum alloy as an example, the application of SPF for making vehicle component is introduced. In general, the rapid SPF process can be used to produce large-scale and complicated parts, such as subway cover parts and high-speed railway head parts with sharp ridge lines to meet the specific strength requirements of the products.