New concept f col f m i ofnon-er ous m at i s s or d or ng f r er al

Expl ve f osi orm i t ng echni ques

TNO Pri M auri s Laborat ns t ory

C.W ent ,Product m anager expl ve zel osi

Out i l ne
Expl ve m at alprocessi osi eri ng
f orm i ng w el ng di

Chal enges i f l n orm i hi perf ng gh orm ance al oys l Basi pri pl c nci es Novelconcept s Exam pl es

Expl ve f osi orm i t ng echni ques

23 M ay 2002

W hat i expl ve f s osi orm i ng?

= Hi Vel t Form i gh oci y ng Expl ve Shockw ave i osi n w at Ki i energy er net c Pl i w ork ast c Advant ages:
pot i f l er recurr ng cost ent al or ow i one- ded t i si oolng unlm i ed pow er ( ze) i t si ext ended f orm abii y lt uni que f orm i schem es ng

Expl ve f osi orm i t ng echni ques

23 M ay 2002

I l rat on of t l ust i echnol ogy

Expl ve: osi
det onat ng chord i t w ork i s he horse shape as appropri e at charge si as appropri e ze at

Process i pract ce n i
buit up w at lerbassi n w at t er ank

Expl ve f osi orm i t ng echni ques

23 M ay 2002

Chal enges i f l n orm i hi ng gh perf orm ance aloys l

Typi al oys cal l
Al i um 2xxx,7xxx,6xxx um ni Ti ani pure,Ti 4V,speci t um 6Al alaloys l ni ckelbased superaloys l ODS aloys ( g.PM 1000) l e. Heatt reat ent requi m s red Li i at ons i pressi capaci y m t i n ng t Hotf orm i ng:cost y t i l oolng;t nni al a case rem oval( ) hi ng; f Ti Forgi ngs:l ong l ead t m es;expensi i ve

Di f cul i i f f i t es n orm i ng:

Chal enges: l
Col f d orm i /f ng orgi beyond presentlm i at ons ng i t i Elm i e rest ct ons on si /l i nat ri i ze oad capaci y t Devel sheetal ernat ves f f op t i or orged com ponent s

Expl ve f osi orm i t ng echni ques

23 M ay 2002

Expl ve m at alprocessi osi eri ng

Expl ve Form i osi ng
shock w ave i w at sand orcont charge n er/ act f f ree orm i ordi f ng e orm i ng,calbrat on i i M echani s sm i nert a- f s i hi vel t f i ef ect n gh oci y orm i ng f orgi ef ect i i eract on w i h di (roni ng f s n nt i t e i ng)

Key el ent off em s orm i ng

unlm i ed si i t ze,l arge t ckness hi st aw ay f eer rom t ensie dom ai nvoke sheari def l n,i ng orm at on i ext ended dynam i f c orm abii y lm i s lt i t

Expl ve w el ng osi di Expl ve engravi osi ng

Expl ve f osi orm i t ng echni ques

23 M ay 2002

I l rat on of M echani :shear l ust i sm def orm at on i

I ard f nw orm i ng
i eased def ncr orm abii y due t lt o com bi ned bi alt axi ensi and on com pressi on si pl posi i l cost di m e, t ve, ow e

e1
Formability limit curve

Extended formability

e2

Expl ve f osi orm i t ng echni ques

23 M ay 2002

M echani :cal brat on sm i i

I pact of sheet ont di m o e pl i hi ast c nge Forgi process ng Consol dat on of shape f i i i or ncreased accuracy
Pl i ast c hi nge

Shock w ave sheet

gap ~ 0. m 2m

DI E Vim pact~ 80 m / s

Expl ve f osi orm i t ng echni ques

23 M ay 2002

Si ul i of cal brat on m at on i i
Detonating cord

Experi ent m s:
FM L and m onolt c sam pl i hi es l oaded by pl i w ave ast c

Pressure wave

Si ul i m at ons
Hydrocodes Num eri si ul i cal m at ons of calbrat on process on i i mi croscal e dam pi and t ng hrough t ckness i pact on di hi m e

Plate Die

First layer yields Second and third layer stay below yield

Cavitationzone

0E+00

2.00E-01

4.00E-01

6.00E-01

8.00E-01

1.00E+00

Expl ve f osi orm i t ng echni ques

23 M ay 2002

Exam pl es
PM 1000 beaded panel
ext ended lm i s i t l oad capaci y t

Ti ani pressure t t um anks

l oad capaci y t di i of l rect on oad,i nert a i

Ari ane V ri f ng ram e

l oad capaci y ( ) t T3! i nert a ef ect i f s

Beer vessel
i d bi

I sogri st f ened case d if

i nhom ogenous part l oad capaci y t

M ani ol ( f d Expl orm ) of

l oad capaci y t cheap di e di ri ed l st but oad

Ari ane v cone panel s

l arge si ze, di ri ed l st but oad i pact ef ect m f s

M ast segm ent

l oad capaci y ( ze,t ckness) t si hi

Expl ve f osi orm i t ng echni ques

23 M ay 2002

10

I egral y st f ened ( urnus affl panel) nt l if Sat w e

Expl ve f osi orm i t ng echni ques

23 M ay 2002

11

I sogri product f i y:proof of d am l concept

Com pl duct ex s
Doubl curved product e s From f at m il sheet m et l led al

Proof of pri pl nci e:

gri on i de & on out de d nsi si Al i um 5000- es um ni seri

Appl ed process: i
adhoc sol i ut on

Resul : t
Good, consi ng deri f rst t al i ri s

Expl ve f osi orm i t ng echni ques

23 M ay 2002

12

Ari ane V Rocket Fram e

Current process:
Drop ham m er f orm i of1. m segm ent ng 4 s Set off our di es Di w ear,surf cont i i e ace am nat on Three i erm edi e heat t nt at reat ent m s

Expl ve f osi orm i ng

Form i of2m m Al i um ng um ni 2024 i T3 condi i n t on Tw o st eps i si e di n ngl e. Elm i i ofheat t i nat on reat ent m I proved propert es m i

Qual f cat on ongoi ii i ng

Scaled development product

Expl ve f osi orm i t ng echni ques

23 M ay 2002

13

Ari ane V cone panel i pact curvi s: m ng

V ~ 50 -100 m / s
++++++++++++

Expl ve f osi orm i t ng echni ques

23 M ay 2002

14

Beaded panel
Aeol ( us X38rudder) beaded panelPM 1000 Hot st ruct ure part I proved f m orm abi i y lt No pressi l m i s ng i t Si e t ngl ool

Expl ve f osi orm i t ng echni ques

23 M ay 2002

15

Ti ani 6Al expl ve f t um 4V osi orm i ng

Bi alext axi ensi at room on t perat em ure
rupt ure t cal ypi

Sol i t be f ut on o ound i n:
m at alf ow ; eri l and/ or i erm edi e heat t nt at reat ent m f orm i schem e ng ( l s cont over def alow rol orm at on i pat h)

Expl ve f osi orm i t ng echni ques

23 M ay 2002

16

I nert a f i orm i ng
Scrap rat reduct on e i
I proved nest ng f ci ar m i or rcul f es ram Expl ve pre- orm i of l osi f ng ong st ps of m et ri al

Rolling / Bending

Exploforming

Ring

Sections

Expl ve f osi orm i t ng echni ques

23 M ay 2002

17

Expl ve w el ng/ addi process osi di cl ng

Expl ve f osi orm i t ng echni ques

23 M ay 2002

18

Expl ve w el ng/ addi osi di cl ng

Room t perat em ure process di m i ar and si i ar m et w el ng ssi l m l al di
e. TiSt ,SS- AlSt ,Nist ,al TiTi g. - eel Cu, - eel - eel so w el ng ofsurf di aces ( anar/ pl curved,sheet f l / oi) l ocalw el ng ( di seam w el d)

M et bondi w i hout m el i re- i f cat on al ng t t ng/ sol di i i St rong bonds Hi def gh orm abi i y f f her processi l t or urt ng Hi heat conduct vi y gh i t Hi el ri conduct vi y gh ect cal i t

Expl ve f osi orm i t ng echni ques

23 M ay 2002

19

W el ng i erf di nt ace TaCu

0. m m 3

Expl ve f osi orm i t ng echni ques

23 M ay 2002

20

Expl ve Seam W el f i osi d at gue perf orm ance

Comparative fatigue in Al 6061-T6
400

Explosion seam welds

Max. Tensile stress [MPa]

300

Parent material
200

GTA welds
100

Tensile tests
0 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04

Flexure tests
1.E+05 1.E+06

Number of cycles to failure

Source: NASA
23 M ay 2002 21

Expl ve f osi orm i t ng echni ques

Expl ve W el ng exam pl osi di e

Ti ani 6Al j nt t um 4V oi
proof of pri pl nci e Expl ve Seam W el osi d

J nt st oi rengt ( ched) h not

prelm i i nary resul 1200 N/ m t m

Pot i t be expl ent al o ored and devel oped Process param et ers
Expl ve charge ( . osi ) Geom et f yer end ry l Preset angl e

Post w el ng: - di
m achi ng ni heat t reat ent m

Expl ve f osi orm i t ng echni ques

23 M ay 2002

22

Set up of expl ve engravi osi ng

Expl ve engravi osi ng

PM L Ri sw i k,24 M ay j j

23

Expl ve engravi of coi i Alpl e osi ng ns n - at

Expl ve engravi osi ng

PM L Ri sw i k,24 M ay j j

24

Det l of coi engravi ai s n ng

Expl ve f osi orm i t ng echni ques

23 M ay 2002

25

Set up of t coi on t pl e i t he ns he at n he bunker

Expl ve engravi osi ng

PM L Ri sw i k,24 M ay j j

26

Det onography:an art st c m et i i hode t o dupl cat nat i e uralm at al( et f eri m al ossi ) l

Expl ve engravi osi ng

PM L Ri sw i k,24 M ay j j

27

Concept t be expl s o ored

Bul khead /hem i sphere
pure hem i sphere eli i lpt cal gas expl ve f osi orm i al ernat ve ng t i

Hybri assem bl d y
expl ve w el ofsold part ont sheet osi d i s o al ernat ve t i egralm achi ng f t i o nt ni rom pl e ( g.al i um ri at e. um ni bs) al ernat ve t f t i o orgi ( ng com pressorbl ade) al ernat ve t cast ng t i o i

St f ened sheetf if orm i ng

si e curvat ngl ure doubl curvat e ure

Expl ve f osi orm i t ng echni ques

23 M ay 2002

28