Materials Science Forum, Vol.447-4, 153-158, 2003
A production system using ceramic die technology for superplastic forming
The recurring costs of producing sheet metal parts using the Superplastic Forming (SPF) and/or SPF combined with Diffusion Bonding process (SPF/DB) have diminished greatly over the past two decades. Today, the most significant roadblock for implementing SPF as a mainstream metal forming technique, for both aerospace parts and other manufactured goods, has become the non-recurring cost and long lead times that are required for the metal dies. This paper examines over a decade of work at Boeing to develop a robust ceramic die production system for the fabrication of aerospace components. Castable ceramic dies are now used extensively by Boeing to produce a broad range of structural airframe parts.
Keywords:aerospace;ceramics;ceramic tooling;die forming;diffusion bonding;hot forming;manufacturing technology;rapid prototyping;SPF;SPF/DB;superplastic forming