explosive froming
TRANSCRIPT
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C. W entzel, Product m anager explosive
t
TNO Prins M aurits Laboratory
New concepts for cold form ing of non-ferrous materials
Explosive form ing techniques
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Outline
Explosive m aterialprocessing
form ing
w elding
Challengesin form ing high perform ance alloys
Basic principles
Novel concepts
Exam ples
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W hat is explosive form ing?
= High Velocity Form ing
Explosive Shockw ave inw ater Kinetic energyPlastic w ork
Advantages: potential for lower recurring cost
one-sided tooling
unlim ited power (size)
extended form ability unique form ing schem es
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Illustration of technology
Explosive:
detonating chord is the w ork
horse shape as appropriate
charge size as appropriate
Process in practice built-up w aterbassin
w ater tank
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Challengesin form ing high
perform ance alloys Typical alloys
Alum inium 2xxx, 7xxx, 6xxx
Titanium pure, Ti6Al4V, specialalloys nickel based superalloys
ODSalloys(e.g. PM 1000)
Difficultiesin form ing:
Heattreatm ents required Lim itationsin pressing capacity
Hotform ing:costly tooling;thinning; alfa caserem oval(Ti)
Forgings: long lead tim es;expensive
Challenges: Cold form ing /forging beyond presentlim itations
Elim inate restrictions on size /load capacity
Develop sheetalternatives for forged com ponents
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Explosive m aterialprocessing Explosive Form ing
shock wave in w ater/sand orcontact charge
free form ing ordieform ing,calibration
M echanism s
inertia-effectsin high velocity form ing
forging effectsin interaction w ith die (ironing)
Key elem entsofform ing
unlim ited size,large thickness
steer aw ay from tensiledom ain,invoke shearing deform ation
extended dynam ic form ability lim its
Explosive w elding
Explosive engraving
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Illustration of M echanism : shear
deform ation Inw ard form ing
increased deform ability due to
com bined biaxial tension and
com pression
sim ple, positive, low cost die
e1
e2
Extended
formability
Formability limit
curve
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M echanism : calibration Im pact of sheet onto die
plastic hinge
Forging process
Consolidation of shape for increased accuracy
DIE
Vim pact~ 80 m /s
sheet
Shock w ave
gap ~ 0.2m m
Plastichinge
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Sim ulation of calibrationDetonating cord
Pressure
wave Experim ents:
FM L and m onolithic sam ples
loaded by plastic w ave
Sim ulations Hydrocodes
Num erical sim ulations of
calibration process on
m icroscale dam ping and through
thickness im pact on die
Plate
Die
Cavitationzone
E+00 2.00E-01 4.00E-01 6.00E-01 8.00E-01 1.00E+00
First layer yields
Second and third layer stay below yield
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Exam ples PM1000 beaded panel
extended lim its
load capacity Ariane V ring fram e
load capacity (T3!)
inertia effects
M anifold (Exploform ) load capacity
cheap die
distributed load
M ast segm ent load capacity (size, thickness)
Titanium pressure tanks
load capacity
direction of load, inertia Beer vessel
ibid
Isogrid stiffened case
inhom ogenouspart
load capacity
Ariane v cone panels
large size,
distributed load im pact effects
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Integrally stiffened (Saturnusw affle panel)
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Isogrid product fam ily: proof of
concept Com plex ducts
Double curved products
From flat m illed sheet m etal
Proof of principle:
grid on inside & on outside
Alum inium 5000-series
Applied process:
ad-hoc solution
Result:
Good,
considering
first trials
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Ariane V Rocket Fram e Current process:
Drop ham m er form ing of 1.4 m segm ents
Set of four dies
Die w ear, surface contam ination
Three interm ediate heat treatm ents
Explosive form ing
Form ing of 2m m Alum inium
2024 in T3 condition
Tw o steps in single die.
Elim ination of heat treatm ent Im proved properties
Qualification ongoing
Scaled development product
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Beaded panel Aeolus(X38-rudder)
beaded panel PM 1000
Hot structure part
Im proved form ability
No pressing lim its Single tool
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Titanium 6Al4V explosive form ing
Biaxial extension at room
tem perature
rupture typical
Solution to be found in: m aterial flow ; and/or
interm ediate heat treatm ent
form ing schem e
(allow s control over deform ation
path)
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Inertia form ingRolling / Bending
Scrap rate reduction
Im proved nesting for circular
fram es Explosive pre-form ing of long
strips of m etal
Ring
Exploforming
Sections
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Explosive w elding/cladding process
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W elding interface Ta-Cu
0.3 m m
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Explosive Seam W eld fatigue
perform ance
Source: NASA
Comparative fatigue in Al 6061-T6
0
100
200
300
400
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
Max.
Tensilestr
ess[MPa]
Tensile tests Flexure tests
Explosion seam welds
GTA welds
Parent
material
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Explosive W elding exam ple
Titanium 6Al4V joint
proof of principle
Explosive Seam W eld Joint strength (notched)
prelim inary result 1200 N/m m
Potential to be explored and
developed
Process param eters
Explosive charge ( .)
Geom etry flyer end
Preset angle
Post-w elding:
m achining
heat treatm ent
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PM L Rijswijk, 24 M ayExplosive engraving 23t
Set-up of explosive engraving
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PM L Rijswijk, 24 M ayExplosive engraving 24t
Explosive engraving of coins in Al-plate
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Details of coin engraving
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PM L Rijswijk, 24 M ayExplosive engraving 26t
Set-up of the coinson the plate in the
bunker
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PM L Rijswijk, 24 M ayExplosive engraving 27t
Detonography: an artistic m ethode to
duplicate natural m aterial (m etal fossil)
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