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Explosive forming techniques

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					           s or d or ng      f r         er al
New concept f col f m i ofnon-er ous m at i s

    osi orm i t
Expl ve f    ng echniques


       ns     t
TNO Pri M auri s Laboratory


                                                 t


       zel                    osi
C.W ent ,Product m anager expl ve
   l ne
Out i

      osi     eri
• Expl ve m at alprocessing
    • form ing
          di
    • w el ng
•       l       n orm i hi perf
    Chal enges i f     ng gh              l
                               orm ance al oys
•       c   nci es
    Basi pri pl
•   Novelconcept  s
•   Exam ples




t         osi orm i t
      Expl ve f    ng echniques             23 M ay 2002   2
       s    osi orm i
W hat i expl ve f    ng?

•       gh   oci y
    = Hi Vel t Form i ng
•   Expl ve ® Shockw ave i
        osi               n
     w at ® Ki i energy ®
         er    net c
       ast c
     Pl i w ork

•   Advantages:
    •       ent al or ow        i
         pot i f l er recurr ng cost
    •        si     oolng
         one- ded t i
    •       i t            si
         unlm i ed pow er ( ze)
    •    extended f       lt
                   orm abii y
    •    unique f     ng
                 orm i schem es




t           osi orm i t
        Expl ve f    ng echniques      23 M ay 2002   3
 l ust i
I l rat on of technology

•       osi
    Expl ve:
    • det    i          s he
         onat ng chord i t w ork
      horse
                       at
    • shape as appropri e
               ze           at
    • charge si as appropri e


           n     i
• Process i pract ce
         l-
    • buit up w aterbassin
          er ank
    • w at t




t        osi orm i t
     Expl ve f    ng echniques     23 M ay 2002   4
    l       n orm i hi
Chal enges i f     ng gh
perf           l
    orm ance aloys
      cal l
• Typi al oys
    •     um ni
        Al i um 2xxx,7xxx,6xxx
    •     t um          6Al
        Ti ani pure,Ti 4V,speci    l
                               alaloys
    •   ni                 l
          ckelbased superaloys
    •         l    e.
        ODS aloys ( g.PM 1000)
    f i t es n orm i
• Di f cul i i f    ng:
    •   Heatt     m    s
              reat ent requi  red
    •     m t i      n      ng
        Li i at ons i pressi capaci yt
    •   Hotform i        l oolng;t nni al a case rem oval( )
                 ng:cost y t i      hi ng; f             Ti
    •   Forgings:long l     i
                       ead t m es;expensive
      l
• Chal enges:
         d orm i /f
    • Col f            ng                  i t i
                ng orgi beyond presentlm i at ons
        i nat     ri i         ze oad capaci y
    • Elm i e rest ct ons on si /l            t
           op       t     i     or orged com ponent
    • Devel sheetal ernat ves f f                  s



t           osi orm i t
        Expl ve f    ng echniques                        23 M ay 2002   5
    osi     eri
Expl ve m at alprocessing
      osi
• Expl ve Form ing
                   n     er/           act
    • shock w ave i w at sand orcont charge
       ree orm i ordi f
    • f f       ng      e orm i      i   i
                               ng,calbrat on
               sm
    • M echani s
         • i    i ef ect n gh      oci y orm i
            nert a- f s i hi vel t f          ng
         • f    ng f s n nt         i     t   e i
            orgi ef ect i i eract on w i h di (roning)
        em  s
• Key el ent ofform ing
         i t
    • unlm i ed si   arge t ckness
                  ze,l     hi
        eer
    • st aw ay f  rom tensie dom ai nvoke sheari def
                           l       n,i          ng        i
                                                    orm at on
    • ext              c orm abii y lm i s
         ended dynam i f        lt i t
      osi     di
• Expl ve w el ng
      osi
• Expl ve engraving



t        osi orm i t
     Expl ve f    ng echniques                           23 M ay 2002   6
  l ust i              sm
 I l rat on of M echani :shear
 def       i
     orm at on
   nw
• I ard form ing
       ncr
    • i eased def         lt
                   orm abii y due to
      com bi      axi ensi and
            ned bi alt      on
      com pression
        m e,      t ve, ow
    • si pl posi i l cost di     e


                    e1
                  Formability limit
                  curve




 Extended
formability
                                   e2



t          osi orm i t
       Expl ve f    ng echniques        23 M ay 2002   7
        sm    i    i
M echani :“cal brat on”
•    m                 o e
    I pact of sheet ont di
•      ast c nge”
    “pl i hi
•        ng
    Forgi process
•          i i              or ncreased accuracy
    Consol dat on of shape f i

                 Pl i
                   ast c                  Shock w ave
                 hinge                               sheet
                                                               2m
                                                        gap ~ 0. m

                                                      DIE
                                  Vim pact~ 80 m /s



t         osi orm i t
      Expl ve f    ng echniques                              23 M ay 2002   8
     m at on     i    i
   Si ul i of cal brat on
                                                                                                                             Detonating cord

                                                      Pressure
        m
• Experi ents:                                        wave
                    i hi
   • FM L and m onolt c sam ples
     l           ast c
      oaded by pl i w ave
    m at ons
• Si ul i                                    Plate
   • “Hydrocodes”
                                                Die
            cal m at ons of
   • Num eri si ul i
        i   i
     calbrat on process on
     microscale
           ng
   • dam pi and t  hrough
      hi       m
     t ckness i pact on di e

                                                 First layer yields
                                                                                                                               Cavitationzone
                                                                      Second and third layer stay below yield




                                     0E+00    2.00E-01        4.00E-01         6.00E-01         8.00E-01        1.00E+00




  t          osi orm i t
         Expl ve f    ng echniques                                                                                         23 M ay 2002        9
Exam ples
• PM 1000 beaded panel                   t um
                                     • Ti ani pressure tanks
    • ext       i t
         ended lm i s                   • l          t
                                           oad capaci y
    • l          t
       oad capaci y                         rect on
                                        • di i of l    oad,i    i
                                                            nert a
• Ari        ng ram e
     ane V ri f                      • Beer vessel
    • l           t T3!
       oad capaci y ( )                    bi
                                        • i d
    • i    i f s
       nert a ef ect                 • I     d if
                                        sogri st f ened case
       f d Expl orm )
• M ani ol (   of                       • inhom ogenous part
    • l          t
       oad capaci y                     • l          t
                                           oad capaci y
    • cheap die                      • Ariane v cone panels
        st but oad
    • di ri ed l                        • large size,
• M ast segm ent                            st but oad
                                        • di ri ed l
    • l          t si     hi
       oad capaci y ( ze,t ckness)         m        f s
                                        • i pact ef ect




t         osi orm i t
      Expl ve f    ng echniques                              23 M ay 2002   10
 nt    l if
I egral y st f ened ( urnus ‘ affl panel)
                     Sat    w     e     ’




t       osi orm i t
    Expl ve f    ng echniques      23 M ay 2002   11
 I     d         am l
  sogri product f i y:proof of
 concept
        ex
• Com pl ducts
            e
     • Doubl curved product s
             l      led
     • From f at m il sheet m etal
              nci e:
• Proof of pri pl
          d    nsi         si
     • gri on i de & on out de
         um ni       seri
     • Al i um 5000- es
      i
• Appl ed process:
     • ad-      ut on
          hoc sol i
       t
• Resul :
     • Good,
             deri
       consi ng
        i     ri s
       f rst t al




 t          osi orm i t
        Expl ve f    ng echniques    23 M ay 2002   12
Ariane V Rocket Fram e
• Current process:
    •   Drop ham m er f     ng     4
                       orm i of1. m segm ents
    •   Set offour dies
    •     e           ace
        Di w ear,surf cont i iam nat on
    •          nt       at
        Three i erm edi e heat t     m
                                 reat ents
      osi orm i
• Expl ve f    ng
            ng          um ni
    • Form i of2m m Al i um
            n        t on
      2024 i T3 condi i
    • Tw o st     n ngl e.
             eps i si e di
        i nat on
    • Elm i i ofheat t        m
                          reat ent
       m              i
    • I proved propert es
      ii i
• Qual f cat on ongoing

                                           Scaled development product

t        osi orm i t
     Expl ve f    ng echniques                             23 M ay 2002   13
Ari                s: m
   ane V cone panel “i pact curving”
                    V ~ 50 -100 m /s   ++++++++++++




t       osi orm i t
    Expl ve f    ng echniques           23 M ay 2002   14
Beaded panel
•       us X38-
    Aeol (     rudder)
    beaded panelPM 1000

•   Hot structure part
•    m
    I proved f        lt
               orm abi i y
•            ng i t
    No pressi l m i s
•     ngl ool
    Si e t




t        osi orm i t
     Expl ve f    ng echniques   23 M ay 2002   15
  t um    4V   osi orm i
Ti ani 6Al expl ve f    ng

•     axi
    Bi alext    on
            ensi at room
      em
     t perature
    • rupt     ypi
          ure t cal




•      ut on o
    Sol i t be found in:
          eri l
    • m at alf ow ;        and/or
       nt      at
    • i erm edi e heat t    m
                        reat ent

    • f     ng
       orm i schem e
       alow     rol
      ( l s cont over def      i
                         orm at on
      path)




t        osi orm i t
     Expl ve f    ng echniques       23 M ay 2002   16
I    i orm i
 nert a f   ng
                                   Rolling / Bending
           e      i
• Scrap rat reduct on
       m            i or rcul
    • I proved nest ng f ci ar
       ram
      f es
           osi      f   ng
    • Expl ve pre- orm i of long
        ri
      st ps of m etal



                                     Exploforming



                                         Ring



                                   Sections

t        osi orm i t
     Expl ve f    ng echniques                  23 M ay 2002   17
    osi     di cl    ng
Expl ve w el ng/ addi process




t       osi orm i t
    Expl ve f    ng echniques   23 M ay 2002   18
    osi     di cl
Expl ve w el ng/ adding

        em
• Room t perat  ure process
    ssi l         m l       al   di
• di m i ar and si i ar m et w el ng
        g. - eel     Cu, - eel - eel so -
    • e. TiSt ,SS- AlSt ,Nist ,al TiTi
          di
    • w el ng ofsurf      pl
                    aces ( anar/            / oi)
                                curved,sheet f l
    • l        di “seam w el
       ocalw el ng (         d”)
      al    ng t          t ng/ sol di i i
• M et bondi w i hout m el i re- i f cat on

•   Strong bonds
•     gh
    Hi def         l t or urt
            orm abi i y f f her processing
•     gh              i t
    Hi heat conduct vi y
•     gh ect cal
    Hi el ri conduct vi y i t



t        osi orm i t
     Expl ve f    ng echniques                      23 M ay 2002   19
    di nt ace Ta-
W el ng i erf   Cu



                                                3
                                               0. m m




t       osi orm i t
    Expl ve f    ng echniques   23 M ay 2002   20
    osi          d at gue
Expl ve Seam W el f i
perform ance
                                               Comparative fatigue in Al 6061-T6

                                400

                                                                                          Explosion seam welds

                                300
    Max. Tensile stress [MPa]




                                                                                                            Parent
                                                                                                            material
                                200
                                                                                     GTA welds

                                100

                                                                  Tensile tests                     Flexure tests
                                 0
                                 1.E+00      1.E+01         1.E+02       1.E+03         1.E+04     1.E+05          1.E+06
                                                                Number of cycles to failure      Source: NASA

t                                   osi orm i t
                                Expl ve f    ng echniques                                           23 M ay 2002    21
    osi     di
Expl ve W el ng exam ple

•     t um    4V oi
    Ti ani 6Al j nt
                  nci e
    • proof of pri pl
           osi
    • “Expl ve Seam W eld”
•    oi
    J nt st     h not
           rengt ( ched)
         i nary resul 1200 N/ m
    • prelm i        t       m
•      ent al o
    Pot i t be expl    ored and
    developed
•   Process param eters
          osi         … )
    • Expl ve charge ( .
              ry l
    • Geom et f yer end
    • Preset angle
•       - di
    Post w el ng:
            ni
    • m achi ng
    • heat t    m
            reat ent



t        osi orm i t
     Expl ve f    ng echniques    23 M ay 2002   22
   -          osi
Set up of expl ve engraving




t       osi
    Expl ve engraving                j j
                              PM L Ri sw i k,24 M ay   23
    osi        ng     ns n - at
Expl ve engravi of coi i Alpl e




t       osi
    Expl ve engraving          j j
                        PM L Ri sw i k,24 M ay   24
   ai s     n
Det l of coi engraving




t       osi orm i t
    Expl ve f    ng echniques   23 M ay 2002   25
   -       he  ns   he at n he
Set up of t coi on t pl e i t
bunker




t       osi
    Expl ve engraving          j j
                        PM L Ri sw i k,24 M ay   26
Det                i i
   onography:an art st c m ethode to
    i e
dupl cat nat        eri m al ossi )
            uralm at al( et f        l




t       osi
    Expl ve engraving             j j
                           PM L Ri sw i k,24 M ay   27
       s o
Concept t be explored
• Bulkhead /hem isphere
    • pure hem isphere
        lpt cal
    • eli i
              osi orm i al ernat ve
    • gas expl ve f    ng t     i
       d
• Hybri assem bly
    •       osi      d      i      s   o
        expl ve w el ofsold part ont sheet
    •     t     i o nt              ni rom pl e ( g.al i um ri
        al ernat ve t i egralm achi ng f       at e. um ni   bs)
    •     t     i o orgi (
        al ernat ve t f    ng com pressorblade)
    •     t     i o       i
        al ernat ve t cast ng
    if
• St f ened sheetform ing
        ngl
    • si e curvature
            e
    • doubl curvature




t           osi orm i t
        Expl ve f    ng echniques                       23 M ay 2002   28

				
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posted:10/6/2011
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