Solutions for Sheet Metal Parts - FormTech

1 Company Presentation_FT Products1 FormTechGmbH- Solutions for Sheet Metal Parts - FormTech GmbH, Mittelwendung 35, 28844 Weyhe/GermanyPhone: +49/4203/8045-0, Fax: +49/4203/8045-29, Company Presentation_FT Products2 FormTechActivities Keytechnology:SPF*, SPF/DB, DB** (hot) Sheet Metal forming(cold) SME cluster Supply Chain for detailsand assemblies RepresentationEMFCO, USAACB, FIMSP, GUS Aircraft Aerospace Engines Automotive Medical General Ind. R & D Feasibility Prototyping Production* SPF =Super Plastic Forming, ** DB = Diffusion Company Presentation_FT Products3 SPF HistoryAuthorsAlloysYear, sourceBengough( + ) brass1912 Rosenhain et and HillsPb-Sn1928 JenkinsCd-Sn, Pb-Sn1928 PearsonPb-Sn, Bi-Sn1934 ChastonPure Pb1935 Bochvar and SviderskajaZn-Al1945 Presniakov and ChervjakovaAl-Cu1958 UnderwoodReview of Soviet works1962 Backofen et Al Blowing of hemisphere1964Ti 6-4 = 834 %Information burst in the field of superplasticity since the end of sixtiesExtruded Bi-Sneutectic 1950% SPF phenomenon under investigation since about 1912 SPF community: 200 experts Company Presentation_FT Products4 SPF Process SchemeGas pressure and/or vacuumTSPFp = f(t)pSPFTSPFp = f(t)pSPFTSPFP hase 1.

2 Start of SPF processPhase 2: Membrane formingPhase 3: Final detail-formingPhase 4: Finished part removedfrom dieSPF is pneumoforming under isothermal Company Presentation_FT Products5 SPF -Technology, Parts and MaterialsMagnesium ~AZ 31, MA 2-2 Aluminium ~AA 5083, 7475 Titanium ~Ti 6-4, BT6, Ti6-2-4-2, 21 S, SP 700, Ti 6-22-22Ti-Al ~gamma TiAlSteel ~ ~IN Company Presentation_FT Products6 SPF Sample Parts Magnesium Certain SPF Mg-alloys show extraordinary SPF properties Very high weight saving potential SPF-properties better than AA 5083 Company Presentation_FT Products7 SPF Sample Parts Magnesium *Sample SPF- Parts * forAston Martin Vanquish manufactured from Al Magnesium-alloy* Photographies of sample Parts by courtesyof Superform Company Presentation_FT Products8 SPF Sample Parts Aluminium *ViperFuel Reservoir Door inner panels Panoz EsperanteDoor outer panels Panoz EsperanteMorgan Cars Front-and Rear Fender* Photographies of Parts by courtesyof Superform Company Presentation_FT Products9 SPF Sample Parts

3 Titanium Elbow , Ti SP 700 Integration, Weight and cost reductionAdvantage SPF-Process: Cost Reduction Weight Reduction Short Schedule Complex design possible Hemispheres , Ti 6-4=> Cost reduction Housing, Ti 6-4, CRES, etc=> Rapid Company Presentation_FT Products10 SPF Sample Parts Gamma TiAl TiAl offers significant weight reduction potential TiAl maintains hi-strength and oxidation resistance up to high temperatures TiAl can replace Ni alloys in hi-temperature Company Presentation_FT Products11 SPF Sample Parts Steel Sample geometry to create new design approachesPossible with very thin materialCharacterisation SPF Design: part geometry not possible with cold formingStrain more than 300% Company Presentation_FT Products12 SPF Technology, Advantages Single Sheet structures with high complexity due to high SPF strain Sheet forming verified for thickness range between and 22mm One step forming process Stress relieving and/or aging heat treatment included in the SPFprocess Forming die inexpensive.

4 Only one cavity and a flat top die necessary Ceramic die concept for rapid prototyping verified Short lead time for feasibility studies, prototypes and small volume production SPF-Production cost effective up to ~20 000 Parts per year Advantage SPF-Process: Cost reduction Weight reduction Rapid prototyping Integral design of complex shapesCost savings up to 40 %-Better material utilisation-Low assembly cost-Reduced part number-Lower die Company Presentation_FT Products13 SPF/DB*-TechnologyHollow blades for fans and compressors Weight reductionIntegrally stiffened fuselage panel (SST**) Weight reduction Performance optimisationCooler outlet duct ( Fighter aircraft) Cost reduction Weight reductionLaminar Flow Panel (RaWid**) Integration of different functions Cost reduction for futureproduction* SPF/DB = Super Plastic Forming / Diffusion Bonding,* *RaWid= Reduction of Aerodynamic Drag, ** SST = Supersonic Company Presentation_FT Products14 Sandwich Components in Reference toborit DesignMaterials.

5 Metal -alloys, (also plastics, textiles possible)Production steps:Hydroformingor SPF, etc. of single core sheetsBonding or soldering etc. of two core sheets forming inner sandwich structureApplication:Flat, metallic, lightweight panels in big dimensions Branches:Aircraft-, automotive-, van-, motorhome, train-system-, shipbuilding industryAdvantages:Low weightLow costVariable strength given by different core geometryHigh rigidity of sandwich-coreSmooth surface possible with face Company Presentation_FT Products15 Sandwich Design TechnologySummary Integrally stiffened, light weight sandwich design 2-, 3-, 4-, n- Sheet technology increases design flexibility Several industrial process alternatives for sandwich Parts : Mg, Al, Ti, SS and Ni-alloys possible by SPF combined with.

6 Welding, TIG, LBW, FSW, Roll spot, Roll seam Brazing or bonding Ti-and steel alloys by SPF and Diffusion Bonding Cold forming combined with bonding Repeatable process with NC-driven-production steps:-DB-Parameters: Temperature, pressure, time, clean atmosphere-Silk -screen printing for stop-off patternCost and weight savings in the range of 40 % and moreSandwich design with:High-corrosion resistant and/or hi-strength alloys and/orlow-weight Company Presentation_FT Products16DB of Plates Heat ExchangersFirst Step:Preparation of surfacesSecond Step:DB-process Design and verification of Inside Channel System much simpler as with machining of solid Company Presentation_FT Products17 Hot Presses SPF, SPF/DB and Hot forming Temperature up to: 1080 C Table size up to: 1800 x 1600 mm Daylightup to: 800 mm FormTechhas own SPF and SPF/DB workshop FormTechowns presses 100, 300 and 800 Company Presentation_FT Products18 SPF SchoolPackage 1: SPF crash course 4 daysPackage 2: Planning, spec s and documentation, SPF demonstration3 daysPackage 3.

7 SPF work including pre-and post processing3 daysXXShop floorXXQuality assuranceXXXM ethods engineerXXDesignerPackage 3 Package 2 Package Company Presentation_FT Products19 SPF Cone Cup Material Test and DatabaseNew alloy Nickel Titanium Aluminium MagnesiumCone Cup TestAnalysisTransfer of optimised SPF-Parameters on SPF Verification sampleConesCRES (x)XX(x)(x)XT1 1 Temperature /FlowstressDetailed definition and verification of SPF Company Presentation_FT Products20 KeyActivities Cold Forming Cost effective production of Sheet Metal Parts Batch size typical for aerospace industry and niche products NC-controlled machines Deep drawing Elastomericforming Bending Welding Materials: Stainless steel, CpTi, Company Presentation_FT Products21 Supply Chain EuropeSheet Metal StructuresAluminium 2xxx, 5xxx, 6xxx, 7xxx, pure Titanium (CpTi):-Grade 1, 2, 3, 4-Ti alloys: -Ti 6-4, Ti 6-2-4-2, 21 S, Ti 15-3-3-3 Superalloys.

8 Inconel, HaynesForming of Sheet Metal and extrusions-Deep drawing-Rubber pad-/ Fluid-cell forming-Stretch forming -Brake forming-Roll forming -Spin forming (hot and cold)MachiningSurface treatment-Chemical Company Presentation_FT Products22 EMFCO-Representation in EUROPEEXOTIC METALS FORMING COMPANYHi-temperature/ Hi-pressure Ducting Company Presentation_FT Products23 EMFCO ProductsEngine/ Bleed Air DuctsA-340 Duct, Inconel 625 Duct System designed andmanufacturedEngine Bleed Ducting SystemEngine Bleed Air DuctsInconel 625 ECS Ducting, Company Presentation_FT Products24 EMFCO ProductsDuct Systems, Ti-and Ni-alloys Parts Scuff plate`,Ti 6-4 KIT of engine ductsInconel625/ 718 APU Mufflers`,CpTiand Ti 15-3-3-3 Company Presentation_FT Products25 EMFCO ProductsA 380 supplierA 380 WorkshareBreakdown EMFCO will supply the APU Ducting System ATA 36 for Airbus Deutschland Ducts in Section 18.

9 And will be made from Ti 15-3-3-3 Ti-alloy Ti 15-3-3-3 results in significant weight Company Presentation_FT Products26 ALTA R Group Simulation of forming processes Simulated dies for elastoformingwith compensated springbackSITIA, F Machines/ presses for Metal forming stretch forming elastoforming SPF Parts manufacturingACB, F andCyril Bath, USAL eading supplier for aeronautical Company Presentation_FT Products27 ALTA R/ ACBC ompetences: forming simulation prototyping tool design and manufacturing technology transfer small batches and series production process trainingProducts:Presses for Stretch forming Elastoforming Super Plastic FormingPart supplier:Production of Stretch form of extrusions Elastomericparts SPF Company Presentation_FT Products28 ALTA R/ ACBP roductsStretch forming pressesSheet stretch formingcurvablejaws max.

10 Jaw distance 12000 mm Jaw length up to 2500 mm Forces between 1000 and 5000 kNrigid jaws max. Jaw distance 6200 mm Jaw length up to 6000 mm Forces between 2000 and 7500 kNProfile stretch forming Forces from 100 to 800 kN Table dimensions up to 2130 x 1270 Company Presentation_FT Products29 ALTA R/ ACBP roductsElastoformand SPF PressesElastoformingSuper plastic formingPlaten dimension up to 2280 x 5300 mmMax. opening from 700 to 2000 mmForce between 2500 and 28000 kN max. pad dimensions 2850 x 1100 mm max. tool height 200 mm pressure up to 1000 Company Presentation_FT Products30 ALTA R/ SITIASIMULATIONS imulation of elastoformingpartsSimulation of Sheet stretch formingSimulation of profile stretch Company Presentation_FT Products31 ALTA R/ Cyril BathReconfigurabledie for stretch forming Replacement of 45% to 75% of existing dies Reduction of capital investment Reduction of storage costs Optimisation of production time:~15 min to create new geometry Rapid and inexpensive prototyping.