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AD 294 949
ARMED SERVICES TECHNICAL INFORMATION AGENCY ARLINGTON HALL STATION ARLINGTON 12, VIRGINIA
UNCLASSIFIED
NOTICE: When government or other drawings, specifications or other data are used for any purpose other than in connection with a definitely related government procurement operation, the U. S. Government thereby incurs no responsibility, nor any obligation whatsoever; and the fact that the Government may have formulated, furnished, or in any way supplied the said drawings, specifications, or other data is not to be regarded by implication or otherwise as in any manner licensing the holder or any other person or corporation, or conveying any rights or permission to manufacture, use or sell any patented invention that may in any way be related thereto.
_______________________________
CJ~
T.S1A
The purpose of this project is to determine the inherent limitations of sheet metal forming processes, to develop the knowledge to significantly advance these and to recommend the manner in which this can be accomplished. This report represents the results of the fourth period, consisting of three months, and covers the final experimental work on tensile testing and forming under combined conditions of high velocity, high temperature and high pressure. Results have been obtained on a projectile impact test fixture, a lowexplosive closed system, a high-explosive open system, an electro-hydraulic open system, an electromagnetic system and conventional presses.
AFSC Aeronautical Systems Division United States Air Force Wright-Patterson Air Force Base, Ohio
NOTICES When Government drawings, specifications, or other data are used, for any purpose other than in connection with a definitely related Government procurement operation, the United States Government thereby incurs no responsibility nor any obligation whatsoever; and the fact that the Government may have formulated, furnished, or in any way supplied the said drawings, specifications, or other data, is not to be regarded by implication or otherwise as in any manner licensing the holder or any other person or corporation, or conveying any rights or permission to manufacture, use, or sell any patented invention that may in any way be related thereto.
Qualified requesters may obtain copies of this report from ASTIA, Document Service Center, Arlington Hall Station, Arlington 12, Virginia.
Copies of ASD Technical Reports should not be returned to the AFSC Aeronautical Systems Division unless return is required by security considerations, contractual obligations, or notice on a specific document.
The purpose of this project is to determine the inherent limitations of sheet metal forming processes, to develop the knowledge to significantly advance these and to recommend the manner in which this can be accomplished. This report represents the results of the fourth period, consisting of three months, and covers the final experimental work on tensile testing and forming under combined conditions of high velocity, high temperature and high pressure. Results have been obtained on a projectile impact test fixture, a lowexplosive closed system, a high-explosive open system, an electro-hydraulic open system, an electromagnetic system and conventional presses.
AFSC Aeronautical Systems Division United States Air Force Wright-Patterson Air Force Base, Ohio
The purpose of this project is to determine the inherent limitations of sheet metal formin processes, to develop the knowledge to eignifica47y advance these, and to recommend the manner in which this can be accomplished. Principal areas of investigation are concerned with the effect that primary process variables such as velocity, temperature, and pressure have on various
period, consisting of three months, which covers the final xperimentl work on tensile testing and forming under combined conditions of high velocity, high temperature, and high pressure. Results have been obtained on a pro-
jectile impact test fixture, low explosive closed system, high explosiveopen system, electro-hydraulic-open system, and electrcagnetic systom and conventional presses.
Results have been obtained for the available ductility for the various
imediately below which optimum formability usually exists. Generally, the ultra high speed systems utilizing shock wave for forming produce superior formability when compared with lower speed systems such as
low explosive and conventional presses. However, the formabl~ty of som materials han been found to be unimproved at these high velocities. Okher materials, such as the titaniume and refractory metalso are not suitble for forming at high speeds except under suitable combined conditions with temperature.
ii
FOREWARD
This Interim Technical Progress Report covers the work performed under contract AF 33(657)-7314 from 1 October 1962 through 31 December 1962. It is published for technical information only and does not necessarily represent the recommendations, conclusions, or approval of the Air Force. This contract is being conducted by the Aeronautics and Missiles Division of the Chance Vought Corporation. It is entitled "Sheet Metal Forming Technology" and is being conducted under William W. Wood, Project Engineer. Others who participated in the research and in the preparation of the reports are: R. E. Goforth, Senior Manufacturing Research Engineer; J. R. Russell, R. A. Ford, D. L. Norwood, C. H. Cole Jr., C. R. Clifton, W. D. Moore, and W. A. Beck, all Manufacturing Research Engineers. This contract was initiated by the Fabrication Branch, Manufacturing Technology Laboratory, AFSC Aeronautical Systems Division, Wright-Patterson Air Force Base, Ohio, and is being administered under the direction of Mr. B. B. Waters (ASRCTF). This is the fourth of a series of four interim reports that will cover the progress of the research through the first fifteen months. A technical report will be written at the end of the fifteenth month and a development plan and handbook will be finished at the end of the nineteenth month.
PUBLICATION REVIEW
Approved by:
C4 -rn' Y/7/e
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ii
21.
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INTRODUCTION .....
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4 4
4
Introduction .
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0 *
Discussion
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4
5
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9. 9 9
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FABRICATION OF PARTS . . . . . . . . . . .i
Introduction ..
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i 11 15
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17
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APPENDIX A
APPENDIX B
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41
102
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.
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120
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. 132
6
.
.
...
...
11
12
3 4 5 6
7a
7b
13
. .. .
14
14 21
. 22
Shallow Recessing Die Configuration ... Experimental Die Formed Parts - 17-7 PH
.
.........
.
.
...
. .
17-7 PH ...
...........
. .
23
9
10a
Elongation Limit Curve Showing Experimental Points Vascojet 1000 ...... ...............
.
....
. .
24
.
-
25
Elongation Limit Curve Showing Experimental Points USS 12 MoV ... .................. . . Experimental Die Formed Parts - Titanium (6A14V) Elongation Limit Curve Showing Experimenta Points
Titanium (6A1-4V)........
. . . . . . . .
26
. -
27
28
-
...
29 30
-
Elongation Limit Curve Showing Experimenta Points L-605 ............. . . . . . . . . . Elongation Limit Curve Showing Experimental Points Rene'41 ....... . . . . . . . . . . . Elongation Limit Curve Showing Experimental Points 2024-0 Aluminum .............. . .. Elongation Limit Curve Showing Experimental Points
17-7 PH (Elevated Temperature -
14
15
31
-
32
-
16
1000F) .
33
FigurePage
17 Elongation Limit Curve Showing Experimental Points A-286 (Elevated Temperature - 1000F) . .. . . . . Elongation Limit Curve Showing Experimental Points Vascojet 1000 (Elevated Temperature - l00*F) . . .. Elongation Limit Curve Shoving Experimental Points USS 12 MoV (Elevated Temperature - 1000F) . . . . .. Elongation Limit Curve Showing Experimental Points Titanium (6Al-4v) (Elevated Temperature - 1200 F).. Elongation Limit Curve Showing Experimental Points
-
33
18
34
34
19
20
35
-
21
35
36
36 37
38
24
25
26
39
40
27
LIST OF TABLES
Table 1 Free Bulge Dome - Low Explosive High Temperature Page
................. ...............
.. ..
..
103 105
121
vi.
Table
Page Deep Recessing - Draw-Low Explosive Air (Room Temperature)....... .... ......... Deep Recessing - Draw-High Explosive Water
(Room Temperature) .
.
1 4
5 6
121
....
. . ..........
122
. ...
123
7
8
Deep Recessing - No Draw - Static Forming (Room Temperature) ....... ... .........
Deep Recessing - No Draw - Static Forming
...................
Deep Recessing - No Draw - Low Explosive Air (Room Temperature)....... . . . . . . . . . . . Deep Recessing - No Draw - Low Explosive Air (Elevated Temperature) .................... Deep Recessing - No Draw - High Explosive Water
(Room Temperature) .................. Deep Recessing - No Draw - Electro-Hydraulic
10 11
12
............. .
No Draw No Draw
....................
Low Explosive Air .............. . . .
129
Shallow Recessing - No Draw - High Explosive Water (Elevated Temperature) ............ . . Shallow Recessing - No Draw - Electro-Hydraulic (Room Temperature) ..... .................
130
17
131
vii
LIST OF GRAPHS
Grah
1 Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at Various Test Temperatures and Velocities - 17-7 PH 5" Gage Length ..... ............ ........
Page
42
Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at Various Test
Temperatures and Velocities - A-286 -5" Gage Length . . ......... ..... ..................... 48
Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at Various Test Temperatures and Velocities - Rene'41 5" Gage Length ...... .. . ... . ... ... Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length At Various Test Temperatures and Velocities - Beryllium 5" Gage Length .......... .................... Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at Various Test Temperatures and Velocities - Molybdenum (.5 Ti) 5" Gage Length ......... ................... Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at Various Test Temperatures and Velocities - Columbium (lOMo-lOTi)5" Gage Length ....... ................... Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at Various Test Temperatures and Velocities - Tungsten 5" Gage Length ......... ................... Uniform Elongation Vs. Forming Velocity for Longitudinal Tensile Specimens at Various Tempera-
-5
59
62
65
68
tures - 17-7 PH - 5" Gage Length ............ 9 Uniform Elongation Vs. Forming Velocity for
...
69
...........
73
....
77
viii
..
81
12
82
13
83
14
...
85
15
86
16
Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at -320*F and Various Test Velocities - A-286 - 5" Gage Length ... .......... . Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at -320F and Various Test Velocities - Vascojet 1000 - 5" Gage Length ....... ...
87
17
89
18
Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at -320*F and Various Test Velocities - USS 12 MoV - 5" Gage Length ........... Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at -320*F and Various Test
Velocities - L-605 - 5" Gage Length ..........
90
19
91
20
.. . . . o . . .
92
Longitudinal Tensile Specimens Elongation Vs. Position of .2 Inch Gage Length at -320*F and Various Test
.....
94
.
96
ix
Graph
24 Uniform Elongation Vs. Forming Velocity for Longitudinal Tensile Specimens at -320*F - Vascojet 1000 511 Gage
Pg
length
. .
. .
. . .
. .
. . . . . . . . . .
97
25
Uniform Elongation Vs. Forming Velocity for Longitudinal Tensile Specimens at -320F - USS 12 MoV - 5" Gage
Length
26 27
. . . . . . . . . . . . . . .
. ..
..
98
Uniform Elongation Vs. Forming Velocity for Lonitudinal Tensile Specimens at -320F - L-605 - 5" Gage Length . . Uniform Elongation Vs. Forming Velocity for Longitudial
99
100 101
106
Uniform Elongation Vs. Forming Velocity for Lonitudinal Tensile Specimens at -320*F - 2024-0 Aluminum . . . . .
29 30
31
Explosive Free Bulge Dome -Average Strain Vs. Velocity -2024-0 Aluminum ... . ........... Explosive Free Bulge Dome-Average Strain Vs. Velocity - 17-7 PH ......................
Explosive Free Bulge Dome - Average Strain Vs. Velocity - A-286 . . . . . . . . . . . .
107
108 109
32
33
Explosive Free Bulge Dome - Average Strain Vs. Velocity - USS 12 MoV . . . . . . . . . . . . . . . . . Explosive Free Bulge Dome - Average Strain Vs. Velocity - Titanium (6A1-4V) ... ... ........
110
11.1
-
34
35
36
112 -
L-605 .
. ..
...
..
113
11
37
Explosive Free Bulge Dome - Average Strain Vs. Velocity - Titanium (13V-lCr-3A1) .... ...... Explosive Free Bulge Dome - Average Strain Vs. Velocity -Molybdenum (.5% Ti) . . . . . . . . Explosive Free Bulge Dome - Average Strain Vs. Velocity - Columbium (10lMo-10 Ti ... . . .
38
. . .
115 116
39
Explosive Free Bulge Dome - Average Strain Vs. .................. Velocity - Tungsten .... Explosive Free Bulge Tube - Average Strain Vs. Velocity - Rene'41 .. ..............
Explosive Free Bulge Tube - Average Strain Vs. Velocity - 17-7 PH ..... ................... Explosive Free Bulge Tube - Average Strain Vs. Velocity - A-286 . ........................ Explosive Free Bulge Tube - Average Strain Vs. ................. Velocity - Vascojet 1000 .... Explosive Free Bulge Tube - Average Strain Vs.
Velocity - Titanium (6A-4V). .
. . . . .... . .
116
.
.
117
118 118
44
119
. 119
45
X1
INTRODUCTION Designers of advanced vehicles of the high velocity aeronautic and aerospace types are placing greater demands on the sheet metal forming industry by designing parts from the high strength thermal resistant alloys that were once made from more formable materials. Added to this are those forming problems associated with the new thermal resistant alloys such as springback and buckling, requiring greater controls in order to maintain the necessary tolerances. A third type of current forming problem is the requirement for close tolerances in both thickness and contour for the more common materials. These greater demands placed on the sheet metal forming industry has generally resulted in increased activity in development of new forming systems. This activity has been extremely great, with particular emphasis placed on the high velocity system such as explosive, electro-hydraulic, electromagnetic and gas expansion. Other high energy forming types such as high temperature, high rubber pressure, and vibration forming have received less attention. In addition, the development of the more conventional forming systems by increasing pressures, addition of heat, and other methods of adaptation has received less attention than the more sophisticated systems. It is now necessary to appraise the sheet metal forming systems by a systematic evaluation of the fundamental parameters governing formability of metals and alloys. The primary purpose of this "Sheet Metal Forming Technology" program is to determine the inherent limitations of sheet metal forming processes, to develop the knowledge to significantly advance these, and to recommend the manner in which this can be accomplished. The approach is to first assess the current state-of-the-art for sheet metal forming by surveying literature and the industry. After the systems were determined that indicate considerable deficiencies as to formability knowledge of the process, a comprehensive experimental program was initiated in order to gain systematic data that will aid in overcoming these deficiencies. These data involve fundamental effects of pressure, temperature and velocity, on a broad range of metals and alloys. From this, recommendations can be made as to the forming systems which hold maximum potential for further development. The program covers the broad class of forming types shown below: I. Conventional Forming A. Brake Bending B. Rubber Forming C. Linear Contouring D. Plane Contouring
E. Spinning F. Bulging
G. Mechanical Die Drawing H. Drop Hammer I. Supplemental Forming
II.
Advanced Methods of Forming A. High Pressure Liquid B. High Temperature C. Explosive D. Capacitor Discharge E. Gas Expansion F. Impact Rubber G. Vibration
Analytical procedures are being utilized to determine the limitations of the better known processes while experimental and analytical procedures are being used to establish the limitations of the more advanced processes, about which less is known from a formability standpoint. The effect of heat, velocity, and pressure is being investigated singularly and in combinations in the following ranges; 1. 2. Temperature: Room temperature - 2500*F Velocity: Static - 1000 Ft/sec. Rubber pressure: Zero.- 100,000 psi
3.
.Materials for the experimental part of the program have been selected from a broad class of alloys and metals as shown below: 1. 2. Aluminum Alloy Stainless Steel 2024-0 17-7 PH
A-286
USS 12 MoV 3. Titanium
6A-4V
13V-llCr-3A1
4. Beryllium
5.
6. 7.
L-605
Molybdenum (j Ti)
Work in this quarter finalized the experimental phase of the program and the results are reported herein. A Technical Report will be submitted as a summary of all previous work. The last period of the contract will be used for finalizing a formability handbook and formulating a future development report. This report will be submitted for a clarification of current sheet metal forming processes and recommendations for future development work needed to significantly advance sheet metal forming technology.
Introduction The test data contained in this report is in the velocity range from static to 620 ft/sec. and the temperature range from cryogenic (-320*F) to 20000F. Using only 5" gage length tensile specimen, these combined velocity-temperature tests were completed for seven materials in the temperature range from ambient to 2000*F for all velocities. These seven materials are those which were not previously reported. Strain distribution curves and uniform elongation vs forming velocity curves are shown in Appendix A, Graphs . through 14. Cryogenic testing in the velocity range from static to 600 ft/sec. has been
completed. Six materials, Titanium (6A1-4V), Titanium (13V-11Cr-3A1), Beryllium, Molybdenum (.5% Ti), Columbium (10 Mo-lO Ti), and Tungsten were not tested because of their brittle nature at cryogenic temperatures. Strain distribution curves and uniform elongation vs forming velocity for the tested materials are shown in Appendix A, Graphs 15 through 28.
Test Procedure Two machines were used for the high velocity tests. The Projectile Impact Tester (CVC XMS 541.013) was used for all ambient and elevated temperature high velocity tests and all cryogenic testing above 150 ft/sec. (See Interim Report II, page 15.) For the cryogenic tests below 150 ft/sec. the Rotary Impact test machine (CvC Xs 541.014) was used with a special chamber around the test specimen for introducing liquid nitrogen as shown in Figure 24 on page 20 of Interim Report No. III. Cryogenic testing with the Projectile Impact Tester was accomplished by inserting the tensile specimens and their coupling tup in a plastic bag which was then filled with liquid nitrogen. The theoretical temperature of liquid nitrogen, -320 0F, was verified by
using a potentiometer.
Discussion The data in this section is derived from the elongation vs. position curves obtained by measuring the grid marks on the tensile specimens. These curves are shown in Appendix A, Graphs 1-7 and 15-21. Because of the large number of specimens tested, it was necessary to show selected curves representative of the strain distribution found for the various velocities and temperatures. Although the interpretation of the data is somewhat arbitrary, the following rules were applied consistently throughout the test series.
i4
(1) The uniform elongation is taken as the average value of elongation outside the necked area. (2) The critical velocity region is established by the following criteria: a) a strain distribution curve that shows a reasonably good reduction in area at fracture, the fracture located at the impacted end of the specimen, a small uniform strain value.
b) c)
The critical velocity of the refractory metals, Columbium (10 Mo-lO Ti) and Molybdenum (.5% Ti), was difficult to determine because of the low value of elongation. For these two materials, particular weight was placed on the position of the fracture rather than the value of the uniform elongation. Due to the increased strength of some materials at cryogenic temperatures, it was necessary to change the specimen size in order to insure a break in the gage section. This was accomplished by machining a specimen with a 2.5 inch gage length and a .125 inch gage width. Tests were preformed which showed a correlation of uniform elongation and maximum elongation between these specimens and the standard specimens.
Results and Conclusions Only those materials shown in Appendix A, Graphs 1 through 7 and 15 through 21
are considered in detail. Graphs 8 through 14, and 22 through 28 show the results of plotting uniform elongation versus forming velocity with a composite graph of the various temperatures given for each material. In Figure 1, the
uniform static strain at various test temperatures is compared to the corresponding dynamic strain values.
Based on Figure 1, (shown on the next two pages), the following conclusions
Material
Combined Temperature.
Velocity Effect
6o
B/
40
-'-
UY'i.LC
17-7 PH
10
0 -320
500
1000
1500
'"
200(
Temperature (F)
60
50
0
V-4
A-286
30
20
10
01
Molybdenum Max
Temperature ("'F)
-320
J
6
]---
I-
500
1000
15002
Temperature (OF)
FIGURE 1:
C0MB
Material
Combined Temperature
Velocity Effect
60
0
Renel'41
30
20
10
-320
500
1000
1500
20
Temperature (OF)
10 Columbium max.
0 -320
o500
1500
Beryllium
14sx.
-320
10
Tungsten
500
1000
1500
Temperature (OF)
i
Max.
0
-320
1500
20C
FIGURE 1: 00MBINE) VELOCITY TWPERATURE EFFECT ON UNIFORK (Concluded) STRAIN FOR LONGITUDINAL TENSILE SPECIMENS
(3)
Dynamic and static loading presents the same ductility for A-286 except for a 15% increase of dynamic over static at room temperature. A-286 shows a maximum ductility at cryogenic with a steady decrease thereafter. Dynamic or static loading at cryogenic (-3200F) is the best forming condition for A-286. Tungsten and Beryllium show the same ductility for static and dynamic loading. An increase in temperature does not increase
(4)
shown at 800OF for static loading. If it is desirable to form Beryllium by a high ener, method, the temperature of the metal should be raised to 1600F. Four materials (Vascojet 1000, USS 12 MoV, 2024-0 Aluminum and L-605) were tested at cryogenic temperature during this period. Elevated temperature testing was completed during the last period and were reported in Interim Report III.
Graphs 24, 25, 26 and 28 in Appendix A show the uniform elongation as a function
of forming velocity. In each case the uniform elongation is room and elevated temperatures as presented in Graphs 1, 2, lower than that at
5 and 6 in Interim
Report III.
Introduction The objective of this phase of testing is to extend the temperature range of the previously determined room temperature data. All materials tested are 0.020 in. and include:
Domes (1)
(2)
17-7 PH
A-286
(7)
(8)
L-605
Rene'41
(3)
Vascojet 1000
(4)
(6)
(5)
uss 12 oV
Titanium (641-4v)
Titanium (13V-JlCr-3A1) Tubes
(9)
2024-0 Aluminum
(1)
17-7 PH
(4)
(5)
Titanium (6Al-4V)
Rene'41
(2) A-286 (3) Vascojet 1000 All tubing is annealed, welded two-inch I.D.
Since high explosive water forming is not readily adaptable to high temperature tests, the elevated temperature work is limited to low explosive testing. Several of the dome materials exhibited a critical velocity in the low explosive range at elevated temperature as shown in Graphs 29-40, Appendix B. Room temperature data, previously determined, are also shown. It should be noted, however, that no critical velocity was reached in the tubing tests at either room or elevated temperature. (See Graphs 41-45, Appendix B.)
Test Apparatus The test specimens for both tubing and dome tests were resistance heated using a 100 KVA low-voltage transformer. All remaining apparatus used in room temperature testing is discussed in detail in previous Interim Reports. (See Interim Report II for tubing apparatus; Interim Report III for dome apparatus.)
Results and Conclusions Domes Eleven of the twelve materials tested showed a definite decrease in elongation at a specific respective critical velocity. Although L-605 exhibited no decrease in elongation, by comparison with'the test specimens of other materials, it is felt that a critical velocity does exist approximtely 100 fps above the highest L-605 test velocity. Additional conclusions can be based upon the results shown in Table 1 and Graphs 29 through 40 in Appendix B. The average elongation of all test materials, except Titanium (13V-lICr-3A1), remains constant or increases with test temperature. Also for the materials exhibiting a critical velocity in the elevated temperature range, there is a definite decrease in critical velocity with increasing temperature. The only exception to this is molybdenum, as shown in Graph 38, Appendix B. It is also evident that a range of increased elongation exists immediately below the critical velocity for all materials except aluminum and refractories. Tubes
Of the five tubing materials tested, Titanium (6A1-4V) showed an increase in elongation with temperature while 17-7 PH and A-286 decreased in elongation. (See Table 2 and Graphs 41 The remaining materials exhibited no change. tests no evidence of a critical tubing the Throughout B.) through 45 in Appendix velocity was observed.
10
FABRICATION OF PARTS
Introduction These series of tests are intended to study and compare the validity of tensile testing and free forming against actual die forming operations. That is, when tensile testing and free forming establishes a given uniform elongation limit the formed part can be expected to fail when this limit is exceeded. Dies that were used in this series were female type tube bulge dies, dome dies, shallow recess dies, and free forming dome dies. Female type tube bulge die tests have been completed and discussed in Interim Report No. III. Dome and shallow recesses have now been completed. Elevated temperature tests, where applicable, are included in this report. Five energy sources are included in these series. (1) Low Explosive - Air They are:
Test Apparatus and F4uipment Forming Mediums: Static - The punch and die setup shown below (Figure 2 1,000 ton press was used to form static, free form domes.
) together with a
FIGURE 2:
SETUP
11
Static shallow recessed parts were formed using femle dies oil a 2,500 ton press equipped with a trapped rubber head . (Figure 3 )
IMai-n Roin
Ruibber Part
B~ase Dolster
FIGURE 3:
-Air
Low Explosive - Both shallow recessed ad domed parts were formed using the low explosive chamber andl hold-down fixture In conjunction with the explosive press. These tools are discussed in Interim Report No. II. High Explosive - Water - Both shallow recessed and domed parts were formed using the necessary tool and high explosive'forming facility shown in Interim Report No. II. Blectro -foramg - Both electrical forming methods utilized the capacitor discharge equipment shown in Interim Report No.* II. The capacitor bank has a capacity of 18,,4oo joules (n13.6 ufd at 20 kilovolts). Capacitance during experimental forming varied from 85.2 jitd to 113.6 /Lfd 'due to the explosion and subsequent replacement of two capacitors. Blectro-hyidraulic parts were formed utilizing the explosive press in conjunction with the standpipe shown in Figure 4I. Electromgnetic parts were formed utilizing the explosive press and a specially designed magntic coil.
12
Eyp],osive Fre.,s
Water Fill
Electrode
FIGURE 1 4:
Dies: Domes and low velocity forming of domes was performed in three different femle dome dies with the following approximte elongations. (See Figure. 5 )
-High
Dome Die #1 Dome Die #2 -2% Dome Die #3 - 57$ Die Cavities were evacuated to approximate ly 28 inches of mercury for all Tose est. art ofthedie contacting the material to be formed were faesprayed with alumina prior to high temperature testing. Static forming of domes was accomplished with a six-inch diameter free form dome die and plunger. Elevated temperature testing was accomplished by heating the plunger and the part to the required temperature.
13
"A"
U"Alt
"All
D14~ "All'
"
l"ici-
3.000
2.000
FIGURE 5:
DME
Shallow Recessing - Parts were formed in three different fe=3le shallow recessing dies with the following approximte elonations. (See Figure 6 )
5
15%
-30
DJFd# gyp.$
FIGURE 6:
14
Die cavities were evacuated to approximately 28 inches of mercury for all tests. Those parts of the die contacting the material to be formed were flame sprayed with alumina prior to high temperature testing.
Dome shaped parts were formed at static velocity using a conventional press setup in a Lake Erie 1,000 ton hydraulic press as shown in Figure 2. Room temperature tests determined that depth to which the part could be recessed before fracture under conditions of ideal draw and complete clamping. For both draw and no-draw tests a lubricant (700 Draw Wax) was used on the punch. No lubricant was used on the drawing surfaces consistent with the experimental conditions of the high velocity tests. The recess depth at fracture was obtained by measuring the position of the main ram. For the no-draw tests adequate blank prevent drawing. On tests where the current flange buckling and fracture larger than that required to provide draw. size and/or hold down pressure was used to optimum draw pressure was used for conof the part, a blank diameter was used no material for the anticipated amount of
For the elevated temperature tests, all parts were formed under no-draw conditions, heat was applied to the punch. Although the die and hold down ring were cooler than the punch, which remained at the test temperature, during the forming operation, it was found that a very slow forming rate (approximately 2 inches/minute) was sufficient to allow the part to come up to temperature prior to contacting the punch. The surfaces of the punch, die and pressure ring were chrome plated to prevent changes in the surface condition of the tools during the test series. No lubricant was used. Shallow recessed, static velocity parts were formed under high pressure by a trapped rubber head, mounted in a single action hydraulic press. No lubrication was used on either the rubber to part interface or on the die. Strain rate, as determined by the pressure build up in the rubber was on the order of
drawing.
Low Explosive - Air The afore mentioned series of dome and shallow recessed dies mounted on a special, mechanical explosive press were used to conduct the low explosive
-
air tests. These tests were performed using Bullseye pistol powder contained in a 700 grain capacity firing chamber. The firing chamber was located approximately six-inches above the part. Explosive charges ranging from 100 to 700 grains, depending on material and gage, were compressed by hand into the firing chamber. Electrical detonation was achieved by use of an Atlas, M-100 match assembly. Velocities were approximated to be in the 100 to 300 fps range.
15
diameter 5356 aluminum welding wire. Water head was 12 inches. Charging voltage varied from the absolute minimum of 6 kilovolts to the absolute maximum of 20 kilovolts. Energy can be calculated from:
2 E = 1/2 CV
where
E C
V is the voltage. Velocities attained are estimated to be in the lower portion of the high explosive
range.
Electromagnet ic All electromagnetic forming was accomplished with a full complement of eight
capacitors. The coil is made up of 22 turns of #I AWG copper wire wound on a three-inch core, to six-inches outside coil diameter. The coil is completely enclosed in glass-filled epoxy, with a 1/16 inch sheet of epoxy-glass over the coil face. Initial attempts to form electromagnetically into a metal die were completely unsuccessful because of the "nagnetic cushion" effect which returns the material to the coil face in a buckled condition. For this reason the free form deep recess die was used, and a #2 shallow recessing die was constructed These dies eliminated the "magnetic cushion" effect. of linen base phonolic. Additional difficulty was encountered with the materials of high electrical
resistivity; it was impossible to obtain sufficient force to deform the material. This problem was solved by the use of a sheet of .063 gage 2024-0
aluminum overlay between the part to be formed and the coil. were exhausted before this portion of the program was reached. Using this
procedure it was possible to fracture the stainless steels and one titanium
alloy and to slightly form the super alloys. The remainder of the materials
16
Voltages used varied from 6 KV for aluminum to 12-18 K for the balance of the materials.
Discussion Deep Recessing: Draw-Room Temperature - Part fabrication under draw conditions was accomplished by static, low explosive, high explosive, and electromagnetic means. Parts were not formed by electro-hydraulic means because it proved impossible to maintain a water head on one side of the part and a vacuum on the other. If the hold down pressure was increased enough to hold the vacuum then the part was not free to draw. The best results were obtained from the static forming process because of slow loading and the ability to control draw. See Tables 3 through 6 Appendix C for the results of the deep recessed, draw testing. High explosive results approached those of static forming except in the Titanium alloys which are sensitive to strain rate. Low explosive - air results are generally lower than either static forming or high explosive results. This is partially due to a powder burning of the part and excessive hold down pressure encountered in the use of the explosive press. Figure 25 illustrates the increase in formability that may be gained by a part formed under a draw condition as opposed to a no-draw condition. Electromagnetic parts were run under draw conditions. because the coil employed in these tests could not withstand those pressures necessary to prevent drawing. Coil design was the first major problem encountered in this part of the program. A useable coil for tube bulging was never devised; however, a coil for recessing, which is marginal, evolved slowly. High flux concentrations in the center of the coil and especially coil durability are still very pressing problems. The inability to form into metallic dies because of the "cushioning effect" and the poor applicability of most materials to this process place severe limitations on electromagnetic forming. Aluminum was best suited to this process due to its good conductivity. However, all those materials that were formed using aluminum overlays yielded results that were as good as the other forming processes. Much work must be done if this process is to become a useful tool of modern industry. No Draw - Room Temperature - Part fabrication under no-draw conditions was accomplished by static, low explosive, high explosive, and electro-hydraulic means.. Figures 7 through 15 illustrate the results of the testing for this portion of the program. The results also appear in Tables 7 through 12 The velocities shown for the different processes are based on those velocities measured in free form, dome testing. These velocities, though not exact, are reasonably accurate and close enough for discussion purposes. The velocities shown for electro-hydraulic forming were estimated since it was impossible to measure velocities electrically by an Eput Timer due to the extremely high voltages used in this process. The percentage of elongation attainable in each die is shown by a dashed line. Those parts,with the exception of static
parts, which fall off one of the die elongation lines do so because of a slight drawing of the part and subsequent correction as to actual elongation.
The curve shown in each figure is that curve obtained in the dome free forming portion of this program.
17
A graph of 17-7 Ph is shown in Figure 7. This graph shows a maximum elongation of 22% in a velocity range from 0 to 600 fps. From 600 fps to critical velocity the maximum elongation rises to 38%. Thus high explosive parts formed in the upper velocity ranges formed in the number two die while the other processes failed in that die. A graph of A-286 is shown in Figure 8. This graph shows a maximum elongation of 25% at static velocity dropping to 17.5% at a velocity range of 60 to 530 fps. From 530 fps to critical velocity the maximum elongation rises to 27%. Once again the high explosive part formed at the upper velocities was good, whereas the other processes at a lower velocity yielded a split part. This graph shows a A graph of Vascojet 1000 is shown in Figure 9. maximum elongation of 17.5% at static velocities, dropping to 15% from 75 to 500 fps. From 500 fps to critical velocity the maximum elongation rises to 20%. A high explosive part is shown .to be a good part at 21.5%. This part falls so near the forming limit that it easily could have failed. Good and split part will both fall on the forming limit curve. A graph of USS 12 MoV is shown in Figure 10. A maximum elongation of 16% is shown for velocities of from static to 600 fps. From 600 fps to critical velocity the maximum elongation rises to 22.5%. Once again a high explosive part formed at the forming limit. Had it not been for a slight amount of draw this part would probably have failed at 26%elongation.
11.
A maximum elonga-
tion of 6%is shown for velocities from 0 to 250 fps. From 250 fps to critical velocity the maximum elongation rises to 10%. The electro-hydraulic and high explosive parts fall beyond the critical impact velocity. Both static forming and low explosive forming yielded split parts on the forming limit curve. A graph of Titanium (13V-llCr-3A1) is shown in Figure 12. A maximum elongation of 10t is shown from a velocity of static to 125 fps. From 125 fps to the critical impact velocity the maximum elongation rises to 13.5%. The electro-hydraulic and high explosive parts fall outside the critical impact velocity and thus failed. The low explosive part fell on the forming limit curve and yielded a split part.
elongation is 17.5%. From 625 fps to the critical impact velocity the mxim= elongation rises to 22.5%. A good, high explosive part fell on the forming limit
curve,: thus indicating that good and bad parts will both fall on the curve.
Had not some drawing been present this part would have failed at 26% elongation. A graph of Rene'41 is shown in Figure 14. A maximm elongation of 18% is shown from 50 to 500 fps. From 500 fps to the critical impact velocity the maximum elongation increased to 22%. A good high explosive part falls on
the forming limit curve.
18
A graph of 2024-0 Aluminum is shown In Figure 15. Maximum elongation from static to critical velocity is 18.5%. The static formed part falls on the forming limit curve. Low and high explosive formed parts as well as the electro-hydraulic part all formed without splitting in the number one die. The forming limit curve is based on uniform or average strain. Thus it is possible to obtain a slightly greater strain than that shown. Such is. the case where the electro-hydraulic and high explosive processes yielded good parts in an area where a split part would be expected. No Draw - Elevated Temperature - Both static and low explosive results closely parallel each other. (See Tables 8 through 10 ). The most noteworthy increase in formability due to elevated temperature occurs in the two titanium alloys. At elevated temperature (1200F) the titanium alloys are capable of forming a good part in Die #1 as opposed to a split part at room temperature. This is true for both static and low explosive forming. See Figure 26 for an example of increase in formbility of titanium at elevated temperatures. At elevated temperatures the low explosive process yielded an increase in formability of .063 gage 17-7 Ph and A-286. Also an increase in formability for .020 gage L-605 and Rene '41. See Figures 16. through 24 for a comparison to free forming elevated temperature results. Shallow Recessing: Room Temperature - Part fabrication was accomplished by static forming, low explosive, high explosive, electro-hydraulic and electromagnetic means. High explosive forming yielded the better results. (See Tables 13 through 17 Appendix C). This was due to the better forming limits of some materials at high velocities and due to a slight drawing of the part. On27 one electromagnetic shallow recessed part was formed due to a lack of power. That being 2024-0 Aluminum in the #2 phenolic die. The part failed. See Figure 27 for an example of parts formed in Dies #1, 2, and 3. Elevated Temperature - The only noteworthy increase in shallow recess formability at elevated temperature occurs in the titanium alloys. These alloys at 1200*F formed a good part in die #1, as opposed to a split part at room temperature. (See Table 15 Appendix C).
19
PROCESS
RESULT
SYKBOL
Static Forming
Good Part
Split Part
A
0
Electro-Hydraulic
Split Part
Good Part High Explosive
-
20
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32
FIGURE 16 ELONGATION LIMIT CURVE SHOWING EXPERIMENTAL POINTS 17-7 PH (ELEVATED TEMPERATMR 10000F)
GOOD PAM
LIY-
AFIT[a7:f
304g:~
20FT.
. . ... . .. ......
,~
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201020
30
00
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30
1 ir -
1.
..... ....
100
200
300
1400
500
600
700
30
T4SPLIT PA
GOOD PART
-A2L1
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FIGURFR19 (LLEA1T
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Velocity Ft/Sec.
4o4
FIGURE 20 ELONGATION LIMIT CURVE SHOWING EOXPERIMENTAL POINTS TITAJIIJ4 (6hi-0i) (EMEATED. TEDeMATURE iO&'i)
-
4'4
100
50
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.....
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NOFIGURE
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23
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(PANec 36R
44
0
FIGURE 2)i ILORITICU LIMIT CURVE SHOWING '' RD0ITA P03IM, 2024-0 AIfLUJE
DIETE NO.R
20
30
iloit ~T
00
100T
200
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70
4[4-4it
rz37
19
38
I
mom*
39i
10
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40z
APPENDIX A
41
GRAPH 1 LOAGITUDIINAL TENSIM SPECIMENS ELONGATION VS POSITION OF .2 INCH GAGE LUM AT VARIOUS TEST TEMPERATMM AND VELOCITIES 17 -7 PH - 5" GAGE LIMME HELD END 60 40 20 -7-7,
+ 0 'V" J1 , , 1", , , 17,, - . -, -1 -- - - ' :. .. fH. ";4
ROM
MATM STATIC
11, 4':L r-14;
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IMPACM END
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41,
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15 Position (Typical) 20 25
42 7-
0MPH 1 (Contnu.d)
60~~
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.063 GAGE
80
STATIC
i~0 .2
60
.2
.2
f i~:7fj~.:~tJr
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20
Position (Typical) 43
GRAPH 1. (Continued)
80
300 Ft/Sec
60 -------.2 207
T~m
60
v77~4i34tL
80
60
580 Frt/Sec
4
20.
..........
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F ......
M
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rr
-1
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20
80
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80
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80
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450 Ft/Sec
0 i jmgj M i4 -----------........... ..........
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4 11 P11111111,11 4
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40
2 20
1-14 +4 I
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44. lit r 11:
0 Position (Typical)
4v
45
GROH 1 (Continued)
60 270
1-/4
Or-
e7
80if
t/e
-4
160
Position~ (Tpcl
15
20
25
46,fK
:1,
GRAPH 1 (Concluded)
60
480 Ft/Sec
07
1' 17
,,~
AI6L
10
15
20
25
Position (Typical)
47
-.
GRAP 2 IITUINAL TW8U19 "ELCHMAION VS POSITION OF .2 AT VARZOUS TEST TEMPIRAWE A-286 - 5" GAGE
ROOK TE467IMMUE
SPECMIS INCH GAGE. LOON AND VELCITIES IflGTR .020 (~l IMPACTED END
HELD END 60
STAIC
4f
ilV
IijT*4~
tI=
60
250 Ft/Sc
20 OV 'TiV,-TTjrd ;-h
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3. 4
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448
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360 Ftfj8ec
80
60
_ _ _ _ _ _I 7 r.
20
0
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1475 Ft/B.ca
E. 2
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80
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mmO
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80
~~~~~STAMIC
___________
2
20
5 15 . Position (Typical)
77
TI
20
25
49
GRIA.PH 2 (Continued)
80
37.5 Ft/Sec
7+T
60
40
. ...
.2
t:V
7 1,7717
20
1
0
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50
GRAPH 2 (Continued)
80
20 ~
62o it/see
LT1 7*~f
60
JSTATIC
-rEl
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0tl
IT .:1tj:fl
u -J
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60
20
10
Positon (Tpica+
-4'
402
GRAPH 2 (Continued)
80
1455 Ft/Sec
40
20
20
414
SecMZ
60
.2
535PtSI
7'I
20
60
0
'I
77
----mA 15
20
25
Position (Typical)
52
GRAPH 2 (Concl1uded)
100
1.25 It/Sec
T.
_____
itifl f:litl
'-' 7;:ti 7-r jt !;;
20
IIjj4___
.55
ft/tit
5:
110
7.
53
GMPH 3 WB3GITUDINAL TMI5IL SPECI34KU EWUQATIONf VS POSITION OF .2 INCH GAGE- I==ff AT VARtIOUS TEST T EATUMlS AND VELOCITIES RMN'1 - 5" GAS' I==Q MWQ TDERATUB ELD MN
80STATIC
_
TwTip IIT
4F1~ r4l
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r
21
14
44
77
54
GRAPE 3 (Continued)
20
1 4
IRA
4A
Th
ft
20
80 80 .39../..
.20 20 139it/ca(p s
80
GRIM! 3 (Coztizaued)
tH
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I I
300 Ft/Sec
. -:
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4i~~~~rr~1
---
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4 -1
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80
530
15
20
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80
--....
Positi-n (Tpial
+57.
...
0PP 3 (Concluded)
10001P 80
-
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sTAT
T'+3T
~~
60 '
lfj
20
2 13. T1
.220
t
+~T'
11o it/se(Tpiae
60
445t
GRAPH 4~ IOWIMMJINAL TENSILE SPEDS ELONGATION VS POSITION OF .2 INCH GAGE LENGTR AT VARIOUS TEST TEMPERTURES AND VELOCITIES ]BERYLLIUM4 5"1 GAGE LENGTH' GAGE WO02 F O00 HELD ED HELD ED 10 STTIC HFT1 -1
fl4ATU END
IE2'4i
U80;
jj .063 GAG
111 u-,-~:;4V~:
-!1
0 10 F/E
'i t#-
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1, i
8o
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40
STATIC
30+
20o .2 10
i"
-
T...111
10 11#1 t
'
t
td
tr~
10 25
2 0 Psitio
15SZ Typial t
20
25
GRAPH 4~ (Continued)
20 FTSEC
q.X
90o0
-44
HG
.03
7060
GRAPE 4 (Concluded)
20
Tw
61
GRtAPH~ 5
IMNITUDIINAL TENSILE SPECI)UNS ELONGATION VS POSITION OF .2 INCH GAIGE IMNOGE AT VARIOUS TEST TEPEN!UIRES AND VELOITIES MoLX3Nmm (.5% TO) -PA( IflG BEUD END
30
ul , , J.; tI
SA
l 4
fc.............
AM
S 20 .211 101
'T7 77
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6....
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T
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2000 *F
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30 20 .2 1.0
0
41.
STATIC Jil
il;; ii
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114'
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Position (Typical)
63
GRMP
5 (Concluded)
55 IT/SEC
30
T;IM
I
10-
+I
Poiho
(Typca1
64t
GUMP 6 LONGITUDINAL TEIWIL spzcims ELONGATION VS POSITION OF .2 INCH GAGE IZNGT AND VEOCITIs AT VARIOUS TEST TORTl GAGE. LENG COLLD(B11 (3.0 IdO-10 Ti)
-5$
HBO END 30
BOOK
STUATICl
.020 .GGZiAT
i'~ i7.:ij.
r-j
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65
MAM 6 (Continued)
ROOK HATURE STATIC
fj
i
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40
30
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GRAPH 15 LONGITUDINAL TENSILE SPECIMENS ELONGATION VS POSITION OF .2 INCH GAGE-LENGTH AT -320*F AND VARIOUS TEST VELOCITIES 17-7 PH - 5" GAGE LENGTH HEWLD 60 220 Fl/SEC IMACTED END
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GRAPH 16
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101
APPENDIX B
10
102
TABLE 1 FREE BULGE DOME LOW EXPL0SIVE HIGH TEMPEATURE TENSILE TESTING DATA Material 17-7 PH Part No. 01101811 01101812 01101813 01101814 01101815 01101816 02102031 02102032 02102033 02102034 02102035 02102036 Vascojet 1000 03101126 03101127 03101128 03101129 03101130 03101131 04103009 04103010 o4103o o01o3o12 o4103013 04103014 0510201705102018 05102019 05102020 05102022 05102023 06102019 06102020 o6102021 06102022 o6102023 06102024 07101019 07101020 07101021 Cbarge Orains (Bullseyve Powder) 60 70 80 60 70 80 70 75 65 70 75 75 80 70 70 75 80 75 70 65 65 70 75 65 70 75 65 70 75 65 70 75 65 70 75 60 70 80
*
Velocity fps 245 250 26o 245 250 260 256 209 240 256 209 240
Temp. OF 500 500 500 10 .1000 1000 500 500 500 1000 1000 1000 500 500 500 1000 1000 1000 500 500 1000 500 1000 1000 500 500 500 1200 1200 1"00 500 500 500 1200 1200 1200 500 500 500
Average Strain % 27.5 27.5 21.5 19.0 28.0 26.0 23.0 26.5 25.5 29.0 24.o 30.5 18.5 14.0 17.5 26.o 8.5 16.0 21.0 25.0 20.0 18.5 21.0 21.0 16.0 13.0 15.5 10.0 12.5 19.0 8.5 20.0 14.5 17.5 18.o 4.0 27.5 29.0 24.5
A-286
?59
232 212 212 232 260 283 261 190 190 261 283 95 158 312 95 158 312 93 124 249 93 124 249 192 212 26o
USS 12 MoV
Titanium (6AI-4V)
L-605
103
TABLE 1
(Continued)
FREE BULWE DOME LOW EXPLOSIVE HIGH TEMPEPATURE TENSILE TESTING DATA Charge-Grains (Bullseye
*
Material
Part No.
Velocity
Temp.
Average
60 70 80
75
Rene'41
70 80 70 75 80
85
(.5% Ti)
75 50 75 85
85
75 75 65 85 85 85 65
65 60 85
60 40 30 30 40 40
104
TABLE 2
Material
Part No.
Temp. OF 500
17-7 PH
01107004
01107005
01107006
50
45
157
140
500
1000
24.9
27.9
60 70 40
75
01107012
A-286 02102011
60
45
182
110
500
500
35.0
20.0
02102012
02102013 02102014
55
65 75
150
190 225
500
500 500
19.3
22.0 19.8
02102015
02102016
45
65
110
190
1000
1000
21.3
19-5
02102017 02102018
Vascojet 1000 03102011
75 55
50
225 150
100
1000 1000
1000
19.7 24.6
19.5
03102012
57
125
1000
19.4
03102013
03102014 03102015
03102016
62
68 50
57
217
230
100
1000 500
500
21-3
18.0 21.4
18.6
100
125
03102017
62
217
500
23.0
03102018
Titanium (6A1-4v) 05102011 05102012 05102013 05102014 05102015
05102016
68
80 70 87 92 80
87
230
80 38 133 220 80
133
500
500 500 500 500 120
1200
22.9
13.9 8.5 10.3 12.0 17.5
14.3
92 70 60
220 38 130
08102005 O810206
08102007
73 65
60
215 175
130
500 500
1000
21.7 24.3
24.95
73 65 55 55
215 175 95 95
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EXPWSIVE
rm2
BUlGE TLUE
30
40M
00 10
30
40
50
00700
800
Velocity (Ft/See) ORAl! 4f3 EXPLOSIVE flUZ BULGE TUBE AVERAGE STRAIN VS VELOCIT A-286
60
50
0 10
200
300 Veoct
e00 (Ft/Boo
.i .t .~ .Yjt . . .. 4 A b1 ;
00
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,
APPENDIX C
120
TABLE 3
(ROOM TEMPERATURE)
Material Part Number Gage Approximate Depth at Fracture (Inches) Do-D Do T Remarks
17-7 PH
A-286
S01203-001
S02101-004
.063
.020
3.00
3.00
.200
.200
37.0
37.0
(A)
(A)
I Vascojet 1000
USS 12 MoV
Ti(6Al-4V) Ti(13V-llCr-3AI)
L-605
.063 .063
.063
3.00 3.00
3.00
.150 .175
.175
.063 .063
.020 .063 .020
1.25 1.60
3.00 3.00 3.00
.031 .063
.163 :163 .175
(A) (A)
(A)
(B)
()
(A
(A)
'e41
S08203-001 S13201-004
.063
3.00 3.00
.155 .200
41.5 37.0
(A) (K) (A
(AS
2024 Aluminum
.063
TABLE 4
MW RECESSING - UW
__________OOM TEMPRATURE)_
Part
LOW EXPLSIVE Aj
Material 17-7 PH
Number L01101-003
Gage .020
Die Number 2
D-D o(C) 6T
Charge 350
A-286
LEoQ3UoX-04 LE01201 -003 LEO1201-w04 102101-003 Lo21ol-04 LEO2201-003 LE02201-04 103101-003 IZO3201-003 LEO101-003 LE04201-003 LO5101-002 I005201-002 L LE06201-002
.020 .063 .063 .020 .020 .063 .020 .063 .020 .063 .02 .063
3 2 3 2 3 2 3 2 2 2 2 1 1 1
350 500 600 350 350 500 700 350 500 250 500 225 225 225
.076 .040 .105" .042 .062 .038 .105 .001 .045 .000 .050 .000 .000 .000
49.4 22.0 46.5 21.8 50.8 22.2 46.5 25.9 21.5 26.o 21.0 6.0 6.0 6.0
I
Vascojet 1000
.063
L06201-003
LE07101-003 LEO7101-004 1E07201-003 I07201-o04
.063 .063
.020 .020 .063 .063
.020
225
250 400 550
.000
26.0
20.9 46.5 21.3
Split Good
Split
Good Split Good
Good
L-605
Rene'41
2 3 2
LED8101-003
3
2
650
350
.132
.027
43.8
23.3
(D)
.oo
.063 .063
3 2 3 121
.048
.060
21.2 51.0
TABLE 4 (Continued)
Part
Material Number Gae
f Die Number
1
2 1 2
D-D
Chage' Do
T Results
Good
Split
Good
2024-0 Aluminum
LE13101-003
113101-004
LE13201-003 LE13201-004
].063
225
350
225
.024
.021
3.6
23.9
350
Split
TABLE 5
Part
MaterialNumber 17-7 PH ae .020 H01102-001
Die
Number 2
1
Charge ( 7 iO
Do-D
D
eT
Results 20.7 Good
A-286
Vascojet 1000
I I
I
I
H30,1102-002 E01203-002
HD2102-001 HE02102-002 HRD2202-001 1302202-002 1303101-001
.020
.063
.020 .020 .063 .063 ".020
.053
.043
37.
2
.090
48.0
21.7
Split
Good
EOI203-001 o.63
3
2 3 2 3 2
20
5 10 10 25 5
.111
.053 .030 .05 .136 .050
145.9
20.7 54.0 21.5 143.4 21.0
Good
Good Good Good Good Good
HE33101-W2
H103201-OO
.020
.o63
3
2
7j
10
.1ol
.02
46.9
21.8
split
Good
H303201-002
M o4102-001 =E14102-002 04202-O1 H304202-O02 HEO5102-001 135102-002 -05201-O2
Uss 22 MoV
.063
.020 .020
3
2 3
271
5 12
.145
42.5
Good
.063
.O63
.051 .119
10
25 5
20.9 45.1
Good Split
.037
.025 .000 .o24
22.3
54.5 26.o 3.6
Good
Good Split
Ti(6A2AV)
3 2 1
52O0-oOl
2
1
10
21
5
.000
.057
Ti(13V-llCr-3A1)
L-6)5
Rene '41
IO62l-
2 1 2
5 2k 10
1
2 3 2 3 2 3 2 3 122
5
5 10 10 30 5 10 10
.023
.050 .094 .041 .131 .048 .115
3.7
21.0
Split
Good
.o63
27f
.125
4.5
Good
TABLE 5 (Continued)
DEEP RECESSING - DRAW HIGH EXPLOSIVE - WATER
Die
Number
(c)
Do-D
"r D T Results
2024-0 Aluminum
SIER13102-002
27
7
20
21.6
46.7
.063
21.8
I6.o 4o
____
Material
Part Number
Results
joules
6 Inches
8 7 7 7 8
34.4
Good
Crack
TABLE 7 DEEP RECESSING - NO DRAW STATIC FOFMING (ROOM TDERURE) Gage .020 .020 .020 .020 .020 .063 .020 .020 .063
Part IApproximate Draw
Material 17-7 PH A-286 Vascojet 1000 USS 12 MoV Ti(6Al-4V) Ti(13V-llCr-3A1) L-605 Rene'41 2024-0 Aluminum
Number So11ol-003 S02101-003 S03113-003 S04101-003 S05101-002 S06202-003 S07101-003 S08101-003 S13201-003
Depth at Fracture 1.95 1.95 1.50 1.95 0.90 1.40 1.85 1.95 1.65 0 0 0 0 0 0 0 0 0
123
TABLE 8
DEEP RECESSING - NO DRAW
TO. T
OF
1000 400
S01101-004 S01101-005
.020 .020
1.40 1.30
12.3 10.8
SO1201005
S02101-005
.063
.020
1.40
1.50
12.3
14.4
so2l
-06,
.o2o
.020 .063
1.4o
1.50 1.50
12.3
14.4 14.4
S03101-004 S03201-002
803201-003
USS 12 oV
S03201-004
.063 .063
.020 .020 .o63
0.90
5.2
0.95
0.90 1.35 1.20
547
5.2 31.2 8.9
650 0
4oo 1m 400
.063
.063
.020
1.25
1.95
1.75
9.7
23.9
19.8
600
1100
1200
Ti(6A1-4V)
$
I
I
S07201-003
S08101-005 S s08101-006 S13201-05 S13201o-06
.063
.020 .020 .063 .063
1.95
1.95 1.75 1.40 1.75
23.9
23.9 19.8 12.3 19.8
750
500 1000 200 400
S13201-007
s13201-0o8
.063
.063
1.75
1.20
19.8
8.9
500
300
S13201-OO9
.063
TABLE 9
1.20
8.9
200
W EXPLOSIVE AIR
Part
Material Number Ge
Die
No. Charge c)
(
Draw
% T Results
17-7
A-286
1 2 1 2 1
2
225
300 300 400 225
300
Vascojet 1000
1 2 1
2
(ROoW TWERATURE)
Material Part Number Gage Die INo. h (C) Charge Draw % T Results
1 2 1 2
1
Ti(6Al-4V)
Ti(13V-llCr-3AI) L-15
2 1 1
1
L62ol-01
LE071O1-001
.o63
.020
1
1
225
225
6.0
6.0
Split
Good
IO71O1-002
Rene'41 LE072Ol-OO1 LE07201-O02 LEO8101-001
.020
.063 .063 .020
2
1 2 1
250
300 400 225
26.0
6.0 26.0 6.0
Split
Good Split Good
LE08l1o-002
2024 -0 Aluminum LE082oI-ooi LM08201-002 LE131O1-001
.020
.063 .063 .020
2
1 2 1
250
300 400 100
26.0
6.0 26.o 6.0
Split
Good Split Good
LE13101-002 LEI32O-O0l
__13201-002
.020 .063
.063
2 1
2
225 200
250
26.0 6.0
26.0
Split Good
Split
TABLE 10
(ELEVATED T4)ERATUR)
Material
17-7 Ph
Part
No.
L01OI-005
il01201-006
Gage
Gag IDi
.020 .063
063
No.
2 2 3 2 2 20 o400
500
C)
%Results
0
ra
Temp
split Good
Split
S10o120l-0O5
A-286 Vascojet, 1000
USS 12 MoV t
.020 .063
063
.020 .o63
.020 .063
3
2 2
2 2
Ti(6Al-4V)
__
1 2 1 2
125
TABLE 10 (cntinued)
DEEP RECESSING - NO DRAW
Part
Material No. Gage
Die
No.
Draw6 T %
0 6.0
Temp.
oI
Results
Ti(13V-llCr-3A1)
LEo62ol-o4 LE06201-005
L-605
Rene'41 2024-0 Aluminum
_ __
IZ07101-005
iao7101-006
1 2 2
200
300
200
26.0
26.0
1200 1200
3
2
300
1400 200
6.0
26.0 26.0 57.0 26.o
Split
split Good Split split Split
split
300 00 122
100 200
50
2 .020 o63 2
26.0
26.o
200
200
TAML
31
o3)
Do T Results Remarks
17-7 Ph
H110o2-003 HE01102-0l
HU1203-003
3 3
2
.025
15
20
HE01203-004
A-286 ascojet 1000
U~
.063
.020 .020 .063 .020 .020
Ti(6A13-4v)
IE03201-003 I
12 MoV
HE02102-003 HE02102-004 HE 222I-003 HE03101-003 HP03101-04 11504102-003 HE012-001O 150420-003 HE05102-003 HE05102-004 HE05201-003 0E05201-04 11506102-003 m6102 -004 1156201-003 1156201-004 1E07101-003 110lO10o 4 H7201-003
71
15 15 10
23.5 56.9
Good
Split Good 1 Good Split Good Good Split
23.5 45.7
45 .7
23.7 21.4 48.0
214.6
(F)
3
2 2
71
.063
3 2
Ti(13V-11Cr-3A1)
.063
.020 .020 .063 .063 .020 .020
I I
t
L-605
.063
2 3 2 2 1 2 1 2 1 2 1 2 3 2
15
15
.010
.1 053 .128 .0141
22.0
15 5
21
o00
15 5
5
5 5
.00
15
20.7 41.2 21.9 26.0 6.0 26.o 6.0 26.0 6.0 26.0
'Good
71 15
15
6.0
22.9 51.6 23.2
Good Split Good Split Split Split Split split4 split split split Good split Good
126
04Mce TEMERATURE)
Material Rene'41 Part No. HE08103-003 GageDie Gage No. .020 2
(E)
Charge 5
I
Results Good
I
Rearks
|
2024-0 Aluminum
.020
.063 .020
.020
3
2 1
2
15 15 2j
5
.077
.041 .000
006
HE13201-003
.063
10
.027
54.3
Split
%
0
6T
Results
Remarks
17-7 PH
A-286
EH01101-01 E31101-002
EHO12O-001 EH02101-001
1 2 2
1
6.0 26.0
26.0 6.0
Good Split
(D) Good
G
(G) (G)
E0m21l-002 EBO31OI-001
EHO I4I-00l
SEO31ox-002
2 1 2
1
(0) (G) ()
(G
Ti6llY) t
Ti(13V-llCr-3Al) L-605 Rene'41
2 1 2
1 1
(a) Gi
(D) (G) (0
E3)7101-002 E
2094-0 Aluminum I.
.020
.020 .020 .063
.020 .020
2
1 2
19.9
11.2 39.8
26.0
6.o 26.0
Split
Good Split
EBHO81O-001 1308101-002
(0) 0)
G) (J)
E O13101-001 ME31Ol--002
IEpo3-OOI
1 2 2
i) (G (G
127
TABLE 13
SHAILOW RECESSING - NO DRAW
(Room
Part
Material No.
STATIC FOI4ING
TWMETR)
Die
Gage No.
Draw
%
j
[tesults
17-7 Ph
S03101-O01 S01101-002
.020 .020
3
1
2 1 2 1 2 1
15.0
Good
A-286
Vascojet 1000
1
S02101-001
802101-002
.020
.020 .020 .020 .020 .020 .020
30.0 5.0
15 . 5.0 15.0 5.0 15.0 5.0
Split Good
Split Good Split Good Split Split
S03113-001
USS 12 NoV
Ti(6A1-4V)
Ti(13V-UlCr-3A1)
L-605 Rene'41 I 2024-0 Aluminum
S06201-001 806201-002
S07101-001
.063 .063
.020
1 2
2 1 2 1 2
5.0 15.0
15.0
Good Split
Good
S07101-002
S08101-001 S08101-002 S13101-001 S13101-002
.020
.020 .020 .020 .020
3
0
30.0
5.0 15.0 5.0 15.0
Split
Good Split Good Split
TAB E 14
SHALLOW RECESSInG - NO DRAW
Material
jGage
.020 .020
Die No.
(c) Charge
Draw T Results
L01101-006 IZo11l1-7
1 2
225 225
5.0 15.0
L301201-007
L02101-007
Lz01O1-06
.063
.020
.020
2
1
2
400
225
300
15.0
5.0
15.0
(D)
LE02201-007
LBO3101-005 L0310l-006 L803201-005 LE03201-006
.063
ISS
2 MoV
2
1 2 1 2
500
15.0
(D)
12"01-005
i oAzo.lo6 LUO21-005 LEOkOI-O06 LE05101-O05
LE05201-005 LE06101-o0
.020
.020 .o63 .063 .020
.063 .02o0
1
2 1 2 1
1 1
300
225 350 225 225
250 200
5.0
15.0 5.0 15.0
Good
Split Spli split
Ti(6Al-4V)
t Ti(13V-llCr-3A1)
5.0
5-0 5.0
Split
Split Split
t L-605
LE07201-06
.063
1 1 2
2
128
500
15.0
(D)
TABLE 14 (Continued)
SHALLOW RECESSING - NO DRAW
Part
No. LE08101-007 LE08101-008 LEo82ol- 06 LE13101-06 LE13101-007 LE13201-007
INo. 1 2 2 1 2 2
Die
(C)Draw
0
LE132o1-006
.063 .063
225
225
5.o
.15.0
God
Split
TABLE 15
SHALLOW RECESSING - NO DRAW LOW EXPLOSIVE AIR
(ELEVATED TEMPERURE)
PMrt
Material 17-7 Ph A-286
f
Temp.
TF TResults
2 2 2
2
15.0
1000
Ti(13V-llCr-3Al)
L-605
.020
tL62oioo8
t
IzO62-oo7
.063
.63 .020 .063 .020 .63
.020 .063
LO71O1-009
2 2 2 2 1 2 1 2 1 2
2
200 400 200 400 200 200 400 400 400 400
200
1000 1200
1200
500
Split Split Split Split Good Split ood Split Good Split
Split
2 2 2 2 2
15.0
129
Part
Material No.
Do
Do-
T
T
Results
-
17-7 Ph
3
2
10 10 10
HE01203-006
A-286
x63
.020 .020 .63 .063 .020
3
2
20
10 10 10 20 5 10 10 2 5
.012
.000 .000
28 7
15.5 29.9 15.0
Split
Good Split Good Split Good Split Good Split Good
Vascojet 1000
3
2 3 1 2 1 2 1
.005
.012
28.7
5.3
EO4020-OO6
WHE0201-005 BE05102-005
.063
o60
063
2
1
1 1
0
10
5
.006
.003
.006 .020 .003
15.4
5.3
14.9 5.0
Split
Goo
Split Split
HE02O1-005
.63
.020 .020
1
2
5
21
.002
.008 .002
5.0
Split
t L-605
o62ol-oo5 HEO7101-005
HEo72ol-oo4 HE07201-005 HW08103-005 HE08103-0o6 HE08203-004
-o3 15
063 063 .020 .020 3 2 3 2 3 2
i00 0
10
=08
.024
-14-7
27.5
5.3 51
Good
Rene '41
20 20 10 10 20
2024-0 Aluminum
.063
.063 020 .020 .63
HE08203-005
BE13101-005 aE13101-o06 HE13201-005 HE132l O6
3
1 2 1 2
20
2 10
.023
.000 .000
27.6
5.3 15.5
Split
Good Split Good Split
5.3
15.5
.o63
130
TABLE 17
Part No.
Gage
Die No.
Energy Kilojoules
Draw
Results
Remarks
17-7 Ph A-286
Vascojet 1000 t
USS 12 MoV
t
EH04101-003 o51ol-003
EHO51Ol-004
.020
2 3 1 2 1 2
1
2 2 1
.020
4. 3 2.7
5.0 Good
H
0
TE6HV)
L65EHO7101-003 Rene'41 2024-0 Aluminum
.020
.020 .020
1
2
2
5.0 Split
15.0
15.0 5.0
H
(G H
EH711o-004
ENO8101-003
11.2 6.1
.020
16.1
13.8
Split
Good Good
.020
EHD8101-04
EH13101-003
.020
.020
3
1
13.8
1.5
EH13101-004
.020
4.3
(H
THRU 17-
(A) - Forming was stopped at a depth of 3 inches. (B) - Part bad puckers on one side.
(C) - Grains of bullseye gnpowder. (D) - Part not formed down completely to die contour.
131
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