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<p>Incremental forming offers unique advantages in producing complex geometries with minimal tooling requirements, making it highly attractive for aerospace, automotive, and biomedical applications. Certain materials, such as titanium and magnesium alloy, are difficult to form in the ambient environment and require heat aid during the forming process. The present research investigates the formability characteristics of thin sheets of titanium grade-5 (Ti6Al4V) alloy fabricated through a warm incremental forming process. The study employs a combination of experimental and metallurgical techniques to analyze the formability. The high-temperature tensile tests were conducted at different strain rates and temperatures to assess the thermomechanical characteristics of the Ti6Al4V. It was observed that beyond 620&#xa0;°C temperature, dynamic recrystallization and softening phenomena occur. These observations led to heat-assisted incremental forming (Ha-IF) experimentations, analyzing parameters such as temperature, feed rate, and step depth in the process. Ha-IF between 550 and 620&#xa0;°C temperatures, with higher step depths, showed greater forming depth and lower component defects. Despite a noticeable increase in ductility above 500&#xa0;°C during tensile testing, formability improvements during Ha-IF were less pronounced. Metallurgical investigations, including SEM and EBSD, confirmed that grain growth, a larger number of active slip planes with low-angle grain boundaries and increased beta grains at elevated temperatures enhance ductility and formability. The results show optimal formability was achieved at higher strain rates, reducing processing time and minimizing environmental contamination.</p>

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Influence of Temperature and Strain Rate on Formability of Ti6Al4V in Warm Incremental Forming

  • 期刊论文

  • 发表日期：

    2025年1月3日

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  • Ankit Kumar Gupta,
  • Mithilesh Kumar Tiwari,
  • Harshal Y. Shahare,
  • Puneet Tandon

摘要

Incremental forming offers unique advantages in producing complex geometries with minimal tooling requirements, making it highly attractive for aerospace, automotive, and biomedical applications. Certain materials, such as titanium and magnesium alloy, are difficult to form in the ambient environment and require heat aid during the forming process. The present research investigates the formability characteristics of thin sheets of titanium grade-5 (Ti6Al4V) alloy fabricated through a warm incremental forming process. The study employs a combination of experimental and metallurgical techniques to analyze the formability. The high-temperature tensile tests were conducted at different strain rates and temperatures to assess the thermomechanical characteristics of the Ti6Al4V. It was observed that beyond 620 °C temperature, dynamic recrystallization and softening phenomena occur. These observations led to heat-assisted incremental forming (Ha-IF) experimentations, analyzing parameters such as temperature, feed rate, and step depth in the process. Ha-IF between 550 and 620 °C temperatures, with higher step depths, showed greater forming depth and lower component defects. Despite a noticeable increase in ductility above 500 °C during tensile testing, formability improvements during Ha-IF were less pronounced. Metallurgical investigations, including SEM and EBSD, confirmed that grain growth, a larger number of active slip planes with low-angle grain boundaries and increased beta grains at elevated temperatures enhance ductility and formability. The results show optimal formability was achieved at higher strain rates, reducing processing time and minimizing environmental contamination.