Forming Plates demonstrator using the CAF technology

Creep Age Forming (CAF) is a forming process that combines creep/relaxation and precipitation hardening of the material. The precipitation hardening aluminum alloys are the typical materials used. The main application of CAF is in the aerospace industry to manufacture structural parts such as wing skins and other complex parts. The process has some advantages when compared to traditional manufacturing techniques. CAF is independent of human skills, has high dimensional repeatability and enables the forming of integrally stiffened parts. However, this process is not widely applied due to its high dependence of product design, the complex spring back prediction and definition of the forming tool surface. This work presents a R&D project that aims to reduce the dependence of design and complexity of spring back calculation through a new way of doing CAF. The Forming Plates project addresses the traditional CAF challenges, opening opportunities to increase the number of parts manufactured by this technology. The use of CAF reduces the recurrent costs of the parts and can improve the mechanical proprieties due to the use of plates with lower thicknesses. In addition, the waste of the machining process is reduced as well as the consumption of aluminum which is in consonance with the ESG requirements. This lecture will focus on challenges of the technology´s demonstrator manufacturing as well as on the results of the teardown campaign carried out on the demonstrator to evaluate the mechanical properties a6er CAF.