The development of Hot Stretch Forming was motivated by the need to design and manufacture Titanium airframe structures for new aircraft with carbon fiber fuselage skins.  Many of these structures are contoured to fit against the inside radius of the fuselage curvature.  By combining traditional stretch forming technology with hot metal forming techniques, the new technology of Hot Stretch Forming (HSF) was developed by the Cyril Bath Company.  This new forming technology allows design engineers to develop a variety of Titanium structure profiles that will be curved to a specific and precise radius prior to final machining.

This new technology is cost effective, repeatable, and available to be used for immediate production in volumes to meet aircraft build rates, now and in the future.  The Hot Stretch Forming process saves both material and machining time; both serious cost issues for today’s aircraft build budgets.  In addition, the process allows for consistent quality, assuring the sustainable attainment of delivery and build schedules.

A general description of the HSF process will be presented, including stretch press designs, control and heating systems, metallurgical issues, tooling issues, and material handling issues.  The benefits of this process in controlling and minimizing residual stress allowing consistent machining will be discussed.