Application of ceramic film as means of lubrication for forming of Ti sheet in a highly localized deformation process

Abstract

Incremental forming is a novel die-less sheet forming process. There is a need for special means to retain lubricant at the tool/sheet interface during forming. To fulfill the stated aim, a porous ceramic film was developed on pure Ti substrate, and it was done through an electrochemical depsition process known as plasma electrolytic oxidation. The film with preferred pore size could be realized after several attempts by varying the processing parameters. In order to characterize the film, a variety of tests including microstructure, film-substrate bond strength and tribological properties tests were conducted. On-job performance of the film was also examined by forming Ti components employing a range of forming conditions. It was found that the proposed method of lubrication was effective, and the plasma eletrolytic oxidation process can be employed to fabricate films on pure Ti sheet to provide means of lubrication during incremental forming.

Keywords

surface film / characterization / plasma electrolytic oxidation / incremental forming / pure titanium

References

[1] Mori Y, Yamazaki M, Shindo H Film Designed for Lubricative Coated Steel Sheets [J]. Prog. Org. Coat., 2000, 40: 119-120.

[2] Wong C C, Dean T A, Lin J A review of Spinning, Shear Forming and Flow Forming Processes[J]. Int. J. Mach. Tool. Manuf., 2003, 40: 1 419-1 435.

[3] Leyens C, Peters M In Titanium and Titanium Alloys [M], 2003 Wiley VCH

[4] Kim H, Altan T, Yan Q Evaluation of Stamping Lubricants in Forming Advanced High Strength Steels (AHSS) Using Deep Drawing and Ironing Tests [J]. J. Mater. Process. Technol., 2009, 209: 4 122-4 133.

[5] Byoni S M, Lee S J, Lee D W, . Effect of Coating Material and Lubricant on Forming Force and Surface Defects in Wire Drawing Process [J]. Trans. Nonferrous Met. Soc. China, 2011, 21: 104-110.

[6] Ji Y H, Park J J Incremental Forming of Free Surface with Magnesium Alloy AZ31 Sheet at Warm Temperatures [J]. Trans. Nonferrous Met. Soc. China, 2008, 18: 165-169.

[7] Chao L J, Chong L, Gui Z T Thickness Distribution and Mechanical Property of Sheet Metal Incremental Forming Based on Numerical Simulation [J]. Trans. Nonferrous Met. Soc. China, 2012, 22: 54-60.

[8] Franzen V, Kwiatkowskia L, Martins P A F, . Single Point Incremental Forming of PVC [J]. J. Mater. Process. Technol., 2008 462-469.

[9] Hussain G, Hayat N, Gao L Pyramid as Test Geometry to Evaluate Formability in SPIF [J]. J. Mech. Sci. Technol., 2012 2 337-2 345.

[10] Jackson K, Allwood J The Mechanics of Incremental Forming [J]. J. Mater. Process. Technol., 2009, 209: 1 158-1 174.

[11] Shim M S, Park J J The Formability of Aluminum Sheet in Incremental Forming [J]. J. Mater. Process. Technol., 2001, 113: 654-658.

[12] Hussain G, Gao A Novel Method to Test the Thinning Limits of Sheet-metals in Negative Incremental Forming [J]. Int. J. Mach. Tool Manuf., 2007, 47: 419-435.

[13] Echrif S B M, Hrairi M Research and Progress in Incremental Sheet Forming Processes [J]. Mater. Manuf. Process., 2011, 99999: 1-7.

[14] Hussaın G, Gao L, Hayat N Improving Profile Accuracy in SPIF Process Through Statistical Optimization of Forming Parameters [J]. Jouranl of Mech. Sci. Technol., 2011, 25(1): 177-182.

[15] Hussaın G, Hayat N, Gao L Pyramid as Test Geometry to Evaluate Formability in Incremental Forming: Recent Results [J]. Jouranl of Mech. Sci. Technol., 2012, 26(8): 2 337-2 345.

[16] Hussain G, Gao L A Novel Method to Test the Thinning Limits of Sheet Metals in Negative Incremental Forming[J]. Int. Journal of Mach. Tool. Manuf., 2007, 47: 419-435.

[17] Wu LX, Xue S A, Zhang W F TA15 Alloy and Its Applications in Plane Constructions [J]. Prog. Ti. Ind., 2003, 20(4): 90-94.

[18] Matthew J, Donachie J R In Titanium and Titanium Alloys [M], 1982 Ohio Metals Park

[19] Lishi W, Qizhou C, Bokang W Analyses of Microarc Oxidation Coating Formed on AZ91D Alloy in Phosphate Electrolytes [J]. Journal of Wuhan University of Technology-Mater. Sci. Ed., 2007, 22: 229-233.

[20] Mua M, Zhoua X, Xiao Preparation and Tribological Properties of Self-lubricating TiO₂/Graphite Composite Coating on Ti₆Al₄V Alloy[J]. Appl. Surf. Sci., 2012, 258: 8 570-8 576.

[21] Fei C, Hai Z, Chen C, . Study on the Tribological Performance of Ceramic Coatings on Titanium Alloy Surfaces Obtained Through Microarc Oxidation [J]. Prog. Org. Coat., 2009, 64: 264-267.

[22] Wang Y M, Jiang B L, Lei T Q, . Microarc Oxidation Coatings Formed on Ti₆Al₄V in Na₂SiO₃ System Solution: Microstructure, Mechanical and Tribological Properties [J]. Surf. Coat. Tech., 2006, 206: 82-89.

[23] Li X, Wu X, Xue W, . Structures and Properties of Ceramic Films on TiAl Intermetallic Compound Fabricated by Microarc Oxidation [J]. Surf. Coat. Tech., 2007, 201: 5 556-5 559.

[24] Minutolo F C, Durante M, Formisano A, . Evaluation of the Maximum Slope Angle of Simple Geometries Carried Out by Incremental Forming Process[J]. J. Mater. Process. Technol., 2007, 194: 145-150.