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Reinforced ceramic dies for superplastic forming operations
Authors:Daniel G Sanders
Affiliation:(1) The Boeing Company, Materials & Process Technology and Phantom Works, P.O. BOX 3707, M/S 5K-63, 98124-2207 Seattle, WA
Abstract:Ceramic dies have been developed to meet the need for a dimensionally stable tool, which can withstand the temperatures (425 to 950 °C) and high forming pressures (up to 7 MPa) that are required for superplastic forming (SPF), superplastic forming with diffusion bonding (SPF/DB), and hot sizing of metal parts. With the improvements that have been made to strengthen fused silica based ceramics, the performance of ceramic tools is slowly closing in on meeting the same forming complexity as corrosion-resistant steel (CRES) dies can achieve. Boeing has successfully superplastically formed jet engine wide chord fan blades using ceramic dies, and many production aircraft parts are being built with Boeing’s patented ceramic die technology. This paper was presented at the International Symposium on Superplasticity and Superplastic Forming, sponsored by the Manufacturing Critical Sector at the ASM International AeroMat 2004 Conference and Exposition, June 8–9, 2004, in Seattle WA. The symposium was organized by Daniel G. Sanders, The Boeing Company.
Keywords:aerospace  automotive  ceramic  ceramic tooling  die forming  diffusion bonding  hot forming  manufacturing technology  rapid prototyping  rebar  reinforcement  superplastic forming  SPF  SPF/DB
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