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Manufacture of a beta-titanium hollow shaft by incremental forming

: Neugebauer, Reimund; Meyer, L.W.; Halle, T.; Popp, M.; Fritsch, S.; John, C.

Preprint urn:nbn:de:0011-n-1645518 (3.8 MByte PDF)
MD5 Fingerprint: 695b9298788cc7b4f74d0295d23df9e1
The original publication is available at
Created on: 9.6.2011

Production Engineering. Research and development 5 (2011), No.3, pp.227-232
ISSN: 0944-6524
ISSN: 1863-7353
Journal Article, Electronic Publication
Fraunhofer IWU ()
incremental forming; spin extrusion; beta-titanium alloys (Ti-10V-2Fe-3Al); microstructure analysis

Excellent mechanical properties and corrosion resistance combined with low weight qualify b-titanium materials for lightweight applications in aviation, automotive and energy engineering. Thus far, actual applications of these materials have been limited due to high material costs and limited processing knowledge. One approach for developing resource-efficient manufacturing methods is the application of incremental forming methods. This article focuses on the development of the incremental spin extrusion process, which creates hollow profiles from solid bars. This method allows hollow shape manufacturing with a much higher flexibility than other forming methods and a significantly improved material utilization in comparison to machining methods, such as deep hole drilling. Beta-titanium alloys basically have very good cold forming suitability and the resulting material properties can be controlled. The application of incremental forming methods with high hydrostatic compressive stress is a promising manufacturing approach. The b-titanium Ti-10V-2Fe-3Al material has an excellent combination of the properties strength, ductility and fatigue strength. In order to utilize these properties the forming conditions and the temperature control need to be optimized. The investigations show that the Ti-10V-2Fe-3Al material can be formed only in a narrow semi-hot forming temperature window. The paper describes the investigation and presents results on the design of partial forming process sequences, forming properties, microstructure formation and failure prevention. The process design objective is a very fine microstructure with a homogeneous secondary a-phase and very small grained b-phase.