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Many aeronautical parts sustain complex geometry are manufactured by SPF processes.
These parts are made mainly from 5xxx alumnium alloys series or, in some cases, from special 2xxx aluminum alloys. See the pictures for examples.
More and more we see manufacturers of aeronautical structures replacing aliminum parts with magnesium ones, mainly in secodary structures or inner fairings. |
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Operating SPF process should be very obvious in case of magnesium alloys!
The reasons are as follows:
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Magnesium SPF as well as aluminum SPF is done at elevated temperatures (350-500°C). Therefore there is no special lineup and cost difference.
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Magnesium sheets may show very good superplasticity in certain conditions. By finding alternative deformation mechanisms the HCP crystalline structure of the magnesium enables very high material elongation at specific temperature range and strain rate (M≥0.3) .
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Aluminum sheets which could be suitable for SPF process usually have medium mechanical properties. Thus, replacing those aluminum alloys by available magnesium alloys does not require a design change and yet, the weight reduction is kept at a 1:1.5 ratio in favor of the magnesium.
The consideration of choosing SPF process to produce a certain part is related to the ratio of part complexity vs. process cost.
Non-recurring engineering (NRE) costs of SPF processes are basically lower than conventional deep drawing processes. |
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Business Jet service door inner Panel:
Made out of Mg Sheet AZ31B 2mm thickness by high strain rate superplastic forming.
Tools design by AMTS.
Process development By AMTS.
Production at PALBAM.
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