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<p>High-end manufacturing sectors extensively use TA18 components in hydraulic and pneumatic pipeline systems because it is a lightweight titanium alloy with exceptional specific strength and corrosion resistance. This study investigates the combination of induction heating and free-bending forming (FBF) technology as a cutting-edge method to improve the formability and geometric accuracy of TA18 Ti alloy tubes, thereby satisfying the growing demand for complexly formed, high-precision tubular components. This combination enables precision-controlled thermal-mechanical deformation, overcoming the forming limitations of traditional methods and facilitating the high-quality, single-step shaping of thin-walled Ti components. Nevertheless, the induction-heating-assisted FBF involves multi-field coupling, multiple interdependent parameters, and non-isothermal deformation conditions, making the plastic deformation behavior of Ti alloy tubes particularly complex. Thus, the goal of this research is to investigate the causes of deformation and the evolution of defects associated with this process, with particular emphasis on the interplay among heat loading, material flow, and stress distribution. To assess and control common faults, a thorough method that combines process optimization, finite element (FE) simulation, and forming mechanism research is used. The findings provide strategic insights into improving the process stability and product quality of Ti alloy tube bending under induction heating conditions, offering guidance for its application in precision-critical industries.</p>

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Understanding the Deformation Mechanisms and Defect Control Framework of Induction Heating-Assisted Free Bending Forming of TA18 Ti Alloy: Theoretical and Simulation-Driven Analyses

  • 期刊论文

  • 发表日期：

    2026年4月2日

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  • Cheng Cheng,
  • Longyin Yuan,
  • Helong Yu,
  • Wei Wang,
  • Ali Abd El-Aty

摘要

High-end manufacturing sectors extensively use TA18 components in hydraulic and pneumatic pipeline systems because it is a lightweight titanium alloy with exceptional specific strength and corrosion resistance. This study investigates the combination of induction heating and free-bending forming (FBF) technology as a cutting-edge method to improve the formability and geometric accuracy of TA18 Ti alloy tubes, thereby satisfying the growing demand for complexly formed, high-precision tubular components. This combination enables precision-controlled thermal-mechanical deformation, overcoming the forming limitations of traditional methods and facilitating the high-quality, single-step shaping of thin-walled Ti components. Nevertheless, the induction-heating-assisted FBF involves multi-field coupling, multiple interdependent parameters, and non-isothermal deformation conditions, making the plastic deformation behavior of Ti alloy tubes particularly complex. Thus, the goal of this research is to investigate the causes of deformation and the evolution of defects associated with this process, with particular emphasis on the interplay among heat loading, material flow, and stress distribution. To assess and control common faults, a thorough method that combines process optimization, finite element (FE) simulation, and forming mechanism research is used. The findings provide strategic insights into improving the process stability and product quality of Ti alloy tube bending under induction heating conditions, offering guidance for its application in precision-critical industries.