Inside a Loire 200T superplastic forming press at the AFRC.
components( such as engine housings, fuselage panels and wing skins) which must meet strict safety and performance criteria.
Using superplastic forming( SPF), the ability to form complex geometries from a single sheet of metal( without welding or joining) can improve structural integrity and performance – particularly in an industry where every ounce of additional weight is crucial.
While its benefits are clear, the process of SPF itself can be time-consuming and capitalintensive. Traditional SPF methods often take several hours per manufacturing cycle with highly controlled temperature and pressure environments that require dedicated forming equipment and specialised expertise.
A combination of these factors has historically limited the ability of other sectors to utilise the technology. More recently, the environmental cost associated with the hightemperature, energy-intensive process has also come under scrutiny, as manufacturers across all industries seek to improve sustainability.
Reducing barriers to entry
As well as unlocking opportunities in other industries, improving efficiencies throughout the SPF process can also support partners in the aerospace supply chain to reduce overheads, lead times and their environmental impact. Innovation is key to overcoming some of the current limitations, and there is a great deal of research being explored by materials scientists all over the world which could help to bring the technology to more companies.
The AFRC superplastic forming project and press.
Core areas such as process analysis, material development and hybridisation are just some of the options being investigated by
teams here at the AFRC and wider National Manufacturing Institute Scotland( NMIS) in collaboration with industry partners. For example, reducing the cycle time using finite element analysis to predict outcomes has allowed us to accelerate forming speeds without compromising material performance.
Alternative alloys that display superplastic behaviour at lower temperatures could also be another exciting area of development, creating opportunities in sectors where there is scope for different materials to be used in lessintensive applications.
In a recent R & D project, we have been working with SDE Technology( supported by global aerospace companies) to develop a new hybrid SPF process using new tooling to reduce process time. The results showed a forming cycle time reduced by around 50 percent and manufacturing costs cut by as much as 25 per cent, compared with traditional methods.
When exposed to high temperatures during SPF, an oxide layer( the alpha case) is also formed on titanium components, which requires powerful acids to remove. The hybrid approach uses less heat and reduces the layer thickness and associated time spent to remove it, boosting its potential for use in new markets.
Preparing for take off
The aerospace sector has long demonstrated the capabilities of SPF, but there is no reason why it should remain exclusive to that field. By embracing hybrid approaches, alternative materials and smarter processing techniques, we can help manufacturers to unlock new opportunities in other areas.
Research and innovation are a core stepping stone to making that possible, with improvements to make SPF faster and more accessible, without compromising on the high standards that have solidified its position as a key technology in aerospace. n
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AFRC workshop.
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FOCUS ON METAL FORMING
EuroSPF conference
Alongside other projects, the AFRC will host the 2025 EuroSPF Conference 2025 from 15-18 September 2025 in Glasgow, Scotland. EuroSPF is a leading forum for researchers, engineers and manufacturers working in SPF, diffusion bonding and related high-temperature sheet processes. The event will showcase the latest breakthroughs, discuss industrial applications and share knowledge across sectors and national borders.
Euro SPF 2025 sessions in Glasgow will take place between NMIS’ s flagship building in the Advanced Manufacturing Innovation District Scotland and the AFRC, a centre of excellence in forming and forging R & D activity. The conference agenda will also include extensive tours of the NMIS facilities, as well as a site visit to an industry partner and trips to the award-winning Riverside Museum and Clydeside Distillery.
See https:// eurospf2025. org /
National Manufacturing Institute Scotland
The National Manufacturing Institute Scotland( NMIS) is a group of industryled manufacturing R & D, innovation and skills facilities supported by a network of Partners across Scotland.
“ The group has a national mandate to create and deliver inspiring, sustainable and translational research and skills for all by accelerating innovation in the manufacturing community. It is where industry, academia and the public sector work together on ground-breaking manufacturing research to transform productivity levels, make companies more competitive and boost the skills of our current and future workforce,” it told ISMR.
The NMIS Group includes the University of Strathclyde’ s Advanced Forming Research Centre( AFRC), Lightweight Manufacturing Centre, Digital Process Manufacturing Centre and researchers working with companies across the manufacturing community in Scotland, the wider UK and beyond. It also includes the Manufacturing Skills Academy and a Capability Network bringing together leading organisations.
NMIS is operated by the University of Strathclyde and supported by the Scottish Government. It is part of the UK’ s High Value Manufacturing Catapult.
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