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Tuesday, June 8, 2004 - 9:00 AM
SPF1.2

Superplastic Forming of Seamless Aluminum Tubes

J. Vetrano, Pacific Northwest National Laboratories, Richland, WA; R. W. Davies, A. Borges, Pacific Northwest National Laboratory, Richland, WA

Superplastic forming of aluminum tubes is an interesting and emerging approach to manufacturing closed cross-section structural members for the aerospace and automobile industries. Typically these tubes are formed by rolling a sheet of superplastic material into a tube shape and seam-welding the cross-section. The problem with this approach is that superplastic materials require a fine grain size (<10 µm diameter) and the welding process often results in a local region with large grains and irregular mechanical properties at superplastic forming temperatures. This presentation describes the process of developing fine grain seamless aluminum tubing that is suitable for superplastic forming, as well as the properties and performance of these materials during commercial superplastic forming. Tubes of AA5083 were extruded at a moderate temperature and then cold worked with sufficient deformation to achieve the necessary fine-grained microstructure. Uniaxial tension tests revealed that under some conditions this material was rendered superplastic with elongations of greater than 400% and strain rate sensitivity of more than 0.5. Forming of tubes using internal gas pressure resulted in hoop strains greater than 1.0 and showed the potential for forming these tubes superplastically and with lower cost than the seam-welded tubes.