Specific mechanical properties of superplastically formed components and resulting applications for vehicles

Kurzfassung

The technical requirements to produce parts as light as possible with more complex geometries are ever increasing in recent years in automotive industries, rail vehicle and aerospace. Manufacturing technologies such as super-plastic metal forming, which had been considered as a niche technology earlier, is now gaining greater technical relevance for industrial size production. The parts that have been generated through super-plastic forming in innovative vehicle for example Mercedes SLS AMG reflect the industrial activity in this area. Manufacturability of thin-walled structures enables lightweight design. Also the tool and manufacturing costs are lower in comparison. However, the main challenge could be found in maintaining exact process parameters. There is a large research potential in super-plastic forming; from the determination of optimal material data through process simulation to manufacturing of real parts and their characterization. In the framework of the project international Bureau of the Federal Ministry of Education and Research UKR005/08 “Manufacture of parts with special properties” a preliminary research work has been carried out. The scientific challenge lies in the characterisation of forming properties of light metal alloys in super-plastic forming. In this preliminary research, the “full factorial experiment” methodology has been applied, regression equations have been developed and a mathematical model derived. This shows interrelationship between mechanical properties of the material and the variable process parameters, leading to material characterization. Hence advantages of cost and time have been achieved; the important parameters for the design of parts through super-plastic forming are determined. The analytical results are then verified with finite element method ─ simulations and through experiments with general parts.