Abstract
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.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig1_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig3_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig4_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig5_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig6_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig7_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig8_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig9_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig10_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig11_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig12_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig13_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig14_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig15_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig16_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs12289-023-01740-9/MediaObjects/12289_2023_1740_Fig17_HTML.png)
Similar content being viewed by others
References
Yuan S (2021) Fundamentals and processes of fluid pressure forming technology for complex thin-walled components. Eng Prc 7:358–366
Bell C, Corney J, Zuelli N, Savings D (2020) A state of the art review of hydroforming technology: Its applications, research areas, history, and future in manufacturing. Int J Mater Form 13:789–828
Wu F, Xu W, Yang Z, Guo B, Shan D (2018) Study on hot press forming process of large curvilinear generatrix workpiece of Ti55 high-temperature titanium alloy. Metals Basel 8(10):827
Trân R, Reuther F, Winter S, Psyk V (2020) Process development for a superplastic hot tube gas forming process of titanium (Ti-3Al-2.5V) hollow profiles. Metals Basel 10:1150
Du Z, Zhang K (2021) The superplastic forming/diffusion bonding and mechanical property of TA15 alloy for four-layer hollow structure with squad grid. Int J Mater Form 14:1057–1066
Sartkulvanich P, Li D, Crist E, Yu K (2016) Influence of superplastic forming on reduction of yield strength property for Ti-6Al-4V fine grain sheet and Ti-6Al-4V standard. Mater Sci Forum 838–839:171–176
Wang K, Wang L, Zheng K, He Z, Politis D, Liu G, Yuan S (2020) High-efficiency forming processes for complex thin-walled titanium alloys components: state-of-the-art and perspectives. Int J Extrem Manuf 2:032001
Wu Y, Liu G, Wang K, Liu Z, Yuan S (2016) Loading path and microstructure study of Ti-3Al-2.5V tubular components within hot gas forming at 800 °C. Int J Adv Manuf Technol 87:1823–1833
Dang K, Wang K, Chen W, Liu G (2022) Study on fast gas forming with in-die quenching for titanium alloys and the strengthening mechanisms of the components. J Mater Res Technol 18:3916–3932
Wang K, Liu G, Huang K, Politis J, Wang L (2017) Effect of recrystallization on hot deformation mechanism of TA15 titanium alloy under uniaxial tension and biaxial gas bulging conditions. Mater Sci Eng, A 708:149–158
Wang K, Liu G, Zhao J, Huang K, Wang L (2018) Experimental and modelling study of an approach to enhance gas bulging formability of TA15 titanium alloy tube based on dynamic recrystallization. J Mater Process Tech 259:387–396
Liu G, Wang J, Dang K, Yuan S (2016) Effects of flow stress behaviour, pressure loading path and temperature variation on high-pressure pneumatic forming of Ti-3Al-2.5V tubes. Int J Adv Manuf Technol 85:869–879
Liu G, Wu Y, Wang D, Yuan S (2015) Effect of feeding length on deforming behavior of Ti-3Al-2.5 V tubular components prepared by tube gas forming at elevated temperature. Int J Adv Manuf Technol 81:1809–1816
Yang J, Wang G, Zhao T, Li Y, Liu Q (2018) Study on the experiment and simulation of titanium alloy bellows via current-assisted forming technology. JOM 70:1118–1123
Liu G, Dang K, Wang K, Zhao J (2020) Progress on rapid hot gas forming of titanium alloys: mechanism, modelling, innovations and applications. Procedia Manuf 50:265–270
Paul A, Werner M, Trân R, Landgrebe D (2017) Hot metal gas forming of titanium grade 2 bent tubes. AIP Conf Proc 1896:050009
Yuan S (2016) Modern hydroforming technology, 2nd edn. National Defense Industry Press, Bei**g
Aksenov S, Kolesnikov A, Mikhaylovskaya A (2016) Design of a gas forming technology using the material constants obtained by tensile and free bulging testing. J Mater Process Tech 237:88–95
Box G, Wilson K (1951) On the experimental attainment of optimum conditions. J R Stat Soc 13(1):1–45
Mrabti I, Hakimi A, Touache A, Chamat A (2022) A comparative study of surrogate models for predicting process failures during the sheet metal forming process of advanced high-strength steel. Int J Adv Manuf Technol 121:199–214
Jiao X, Wang D, Yang J, Liu Z, Liu G (2019) Microstructure analysis on enhancing mechanical properties at 750 °C and room temperature of Ti-22Al-24Nb-0.5Mo alloy tubes fabricated by hot gas forming. J Alloy Comp 89:639–646
Wu R, Liu X, Li M, Chen J (2022) Investigations on the process window for friction stir assisted double-sided incremental forming with synchronous bonding of steel and aluminum alloy sheets. Int J Mater Form 15:3
Wang K, Shi C, Zhu S, Wang Y, Shi J, Liu G (2020) Hot gas pressure forming of Ti-55 high temperature titanium alloy tubular component. Materials 13(20):4636
Wang K, Jiao Y, Wu X, Qu B, Wang X, Liu G (2021) A novel composited process of solution treatment-hot gas forming and stress relaxation aging for titanium alloys. J Mater Process Tech 288:116904
Tang Z, Chen J, Dang K, Liu G, Tao K (2019) Experimental investigation into the electropulsing assisted pulsating gas forming of CP-Ti tubes. J Mater Process Tech 278:116492
Wang K, Liu G, Zhao J, Wang J, Yuan S (2016) Formability and microstructure evolution for hot gas forming of laser-welded TA15 titanium alloy tubes. Mater Des 91:269–277
Chen Y, Han G, Li S, Li Y, Li Z, Lin Z (2021) Time-dependent spring-back prediction with stress relaxation effect for non-isothermal hot stam** of titanium alloy sheets. Int J Adv Manuf Tech 115:637–653
Pérez C, Odenberger E, Schill M, Niklasson F, Åkerfeldt P, Oldenburg M (2021) Spring-back prediction and validation in hot forming of a double-curved component in alloy 718. Int J Mater Form 14:1355–1373
Jiang S, Zhang K (2009) Study on controlling thermal expansion coefficient of ZrO2-TiO2 ceramic die for superplastic blow-forming high accuracy Ti–6Al–4V component. Mater Des 30:3904–3907
Wang G, Jia H, Gu Y, Liu Q (2018) Research on quick superplastic forming technology of industrial aluminum alloys for rail traffic. Defect Diffus Forum 385:468–473
Funding
This work was financially supported by the National Natural Science Foundation of China (No. U1937204 and 51401065), Heilongjiang Provincial Natural Science Foundation of China (No. LH2021E058) and China Postdoctoral Science Foundation (2019M661278 and 2021T140153).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher's note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Qu, B., Wang, L., Wang, K. et al. Optimization of hot gas pressure forming process for titanium alloy component. Int J Mater Form 16, 18 (2023). https://doi.org/10.1007/s12289-023-01740-9
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s12289-023-01740-9