Superplastic forming of a complex shape automotive component with optimized heated tools

Superplastic forming (SPF) commonly requires industrial presses with an integrated large furnace able to uniformly heat the tools and the blank. In this work the feasibility to form via SPF an automotive component using a different heating approach was investigated. The heat is localized only where it is really needed embedding electric heating elements directly in the forming tools. Preliminary numerical simulations of the heating phase were aimed at calculating the electrical power and at choosing a suitable positioning of the heating elements. Further forming simulations were run to calculate the pressure profile. SPF experiments were finally conducted and sound components were obtained saving energy costs and using a common industrial press with lower investment costs.