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Forming Technology of Large-Diameter, Thin-Walled and Weldless Tube of TC4 Al­ Loy

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Forming Technology of Large-Diameter, Thin-Walled and Weldless Tube of TC4 Al­ Loy Forming Technology of Large-diameter, Thin-walled and Weldless Tube of TC4 Al­ loy Qi Jun Li Qi Wang Cao Gen Yao Qun Shan Si Yuan Huang Aerospace Research Institute of Material and Processing Technology ,Beijing 100076 In this paper, effect of parameters of spin forming on large-diameter, thin-wall and weld less tube of TC4 alloy was analyzed by finite element anal­ ysis. In addition, the spinning technology for manufacturing the TC4 tube was optimized and the microstructure and the properties of original material were investigated. Results show that the TC4 alloy tube with high precision is successfully manufactured by spin forming technology. After spinforming and heat treatment, the microstructure and property can be improved. Keywords: TOI alloy, large-diameter ,thin-walled ,weldless, spinforming alloy and also the flow stress is low. I. Introduction In order to achieve the goal of light weight, large dimension and high strength materials, the large-diam­ eter and thin-wall and weldless TC4 alloy tube was hot "'c -3 preferable widely applied in the space flight system. At present, - -4 fonning region there are few references about the manufacturing tech­ -5 nology of the large-diameter, thin-wall and weldless -6 TC4 alloy tube. Due to the large resistance to deforma­ -7+-'-"'=.-~~T'-'-'--"=..."-'--."'-',,__,_-'.-'--'--; tion, it is difficult to manufacture the TC4 alloy tube 700 750 800 850 900 950 T,"C by usual technology. The spinforming is an advanced technology for manufacturing the TC4 alloy tube. Figure I. The hot forming chart of TC4 alloy However, there are many factors affect the spinform­ Heat treatment was conducted in order to stabilize ing of TC4 alloy especially for the tube. In the back­ 0 5 the microstructure and reduce the relaxation of residual ground of the TC4 alloy tube (the size <1>6 70;i · X 400 stress after spinning deformation. The microstructure 0 2 X 2;i · mm) served as a component in aerospace, the of the alloy after heat treatment was analysis. spinforming technology of a TC4 alloy was investiga­ ted. 3. Results and Discussion 2. Experimental 3. I Analysis of Technological Parameter Figure 2 shows the axial displacement of different 2. I Materials ratio of feeding. According to Figure 2, the influence of The TC4 alloy plate, with a thickness of 10 - the ratio of feeding on the metal flow can be observed. 12mm and diameter of </>1150-1200 mm, was punched When the ratio of feeding is quite small, the contact into a tube. material region between roller and raw materi.al is very small and the distribution of deformation is inhomoge­ 2. 2 Test Technology neous in thickness direction. It is easy to produce the On the basis of finite element model <FEM) simu­ band and follow slight bulge. While the ratio of feeding lation spinforming process, the technological parameter is large, the axial displacement in front of roller is also of spinforming and the technology of temperature con­ large, causing pile up and bulge, the metal axial flow is trol was investigated to make sure the forming and pre­ blocked; The metal axial flow is steady when the ratio cision of the work piece. Because the spinforming cau­ of feeding is 0. 6 mm/ r. ses the TC4 alloy to fracture in room temperature, the Figure 3 shows the axial displacement of the ratio hot spinforming must be carried out, which can enhance of thinning. The corresponding curve with the axial dis­ the deformation capability and reduces the resistance to placement is indicated as Figure 4. deformation and the components snapping back. At It is clear from Figure 3-Figure 4 that the axial present, the hot spinforming is the main spinning tech­ displacement increases with the increase of the ratio of nology for manufacture titanium components. Figure 1 thinning. This indicates that the increase of the ratio of shows the hot forming chart of TC4 alloy in some thinning can increase the axial flow. Also, the distribu­ strain by thermal simulation experiment. Hot forming tion of the axial displacement in thickness direction region is preferable from 800 to 900"C. During this re­ changes with the ratio of thinning changed While during gion, dynamic recrystallization is easy to occur for TC4 20 %-40 % , the distribution is even, while more than • 2008 • Proceedings of the 12'h World Conference on Titanium 2.993e-001 4.337e-001 2.609e-001 3.854e-001 2.225e-001 3.371e-001 1.840e-001 2.888e-001 J.456e-001 2.405e-001 J.072e-00 1 J.922e-001 6.872e-002 1.439e-00 1 3.029e-002 9.56 1e-002 -8. l 47e-003 4.73 le-002 -4.658e-002 -9.930e-004 -8.501 e-002 -4.930e-002 ( a ) 0.2mm/ r ratio ( a) 20% ratio 6.712e-001 6.712e-001 5.986e-001 5.986e-001 5.260e-001 5.260e-001 4.533e-001 4.533e-001 3.807e-001 3.807e-001 3.0Sle-001 3.081e-001 2.354e-001 2.354e-001 1.628e-001 l .628e-001 9.016e-002 9.016e-002 J.752e-002 J.752e-002 -5.51 1e -002 -5.5 11 e-002 ( b ) 40% ratio ( b) 0.6mm/r ratio 8.480e-001 l.051 e+OOO 7.337e-001 8.654e-00 1 6.195e-001 6.794e-001 5.053e-001 4.934e-001 3.91 le-001 3.074e-001 2.768e-001 l.214e-001 l.626e-OOI -6.455e-002 4.837e-002 -2.505e-001 -6.586e-002 -4.365e-001 -1 .801e-001 -6.225e-001 ( c) 1.4mm/ r ratio -2.943e-001 ( c) 60% ratio Figure 2. The axial displacement of different ratio of feeding Figure 3. The axial displacement of different ratio of thinning 60 %, the axial displacement concentrates in the outer layer and deformation of metal in inner layer is difficult Figure 4 also demonstrates the situation of bulge because of bulge. with different ratio of the thinning. When rollers axially 9. Aerospace Applica tions • 2009 • ----60% flow of metal and plump up ( Figure 7) in the back of 1.0 ---- 40% 20% roller. Therefore, the auxiliary spinning technology was E E 0.8 used to expand the diameter of work piece between -::::- passes of spinfoming, ca using the work piece to sepa­ i:i E 0.6 rate from the mandrel. The metal axial fluidity is corre­ "u 0."' spondingly enhanced. At last , the typical quality prob­ :;"' 0.4 lem such as indirect extrusion and bulge , which appears -;;; ·x easily during multi-passes spinforming of the large di­ "' 0.2 ameter and thin wall T C4 alloy tube, was solved. 0.0 0.5 1.0 1.5 2.0 2.5 3 .0 thickness direction/ mm Figure 4. Corresponding curve with the axial displacement compress blank, the metal piles up in the deformational region, which lead to the deformation of bulge. While the ratio of thinning is from 20 % to 40 % , the spin­ forming process can be normally carried out because that the bulge remains slight and stabl e. While more than 60 % , peeling happens because of seriously bulge (Figure 5). Figure 7. Plump up 3. 3 Result Analysis on Temperature Control The temperature control is one of the key aspects which affect the spinforming of the large diameter and thin wall T C4 alloy tube. Because the size of the raw materials of spinning tube is large , it is difficult to maintain high temperature for the entire work piece and ensure the uniform of temperature. For stabilize Figure S. Peeling the temperature of deformation region , the technology The results of FEM simulation show that it is of district temperature control is used during the de­ suitable for spinforming and process control when the formed region, the deformation region ( including region ratio of feeding is 0. 6mm/ r and the ratio of thinning is of contact in front of roller) and undeformed region. Meanwhile, the temperature of mandrel was controlled in the region of 20 %~40%. before spinforming in order that the temperature of 3. 2 Analysis of Spinning Technology mandrel distributed unifomly and the inflationis con­ sistent The heat transfer rate of material is also re­ The experiment is carried out by multi-passes duced, which is advantage for temperature control of spinforming. During the following pass of hot spin­ the materials. forming, the work piece will contract and enclasp the Figure 8 shows the large diameter and thin wall mandrel. In adition, the metal axial flow is blocked in T C4 alloy tube with good quality by spinforming tech­ unformed section and forming section and bulge occurs 0 5 0 2 nology( ct> 670;i · X 400 X 2;i · mm). (Figure 6) in front of roller, which lead to the reverse Figure 8. Weldl ess tube of TC4 alloy The tube is cut off and precisely machined in the in­ ner surface and the outer surface. Finally, the large-diame­ Figure 6. Bulge ter and thin-wall and weldless TC4 alloy tube with high • 2010 • Proceedings of the 12'h World Conference on Titanium precision is successfully manufactured (Figure 8). ent conditions. It is clear that the strength changes slightly and plasticity increase markedly. This results 3. 4 Analysis of Microstructure and Properties show that the hot spinforming improved the properties Table 1 shows the properties of samples in differ- of TC4 alloy. Table 1. The results of testing properties the properties in room temperature Test status Ultimate tensi le strength Yield strength ao.
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