AFRC unlocks new paths for superplastic forming

Dr Hosam Elrakayby, Forming Team Lead, Advanced Forming Research Centre (AFRC), University of Strathclyde (UK) outlines how, by embracing hybrid approaches, alternative materials and smarter processing techniques, AFRC aims to help manufacturers unlock new opportunities for superplastic forming (SPF) beyond aerospace and defence.

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In the US$-900 billion aerospace industry, manufacturing technologies must meet some of the most demanding standards of performance, precision and reliability. Superplastic forming (SPF), for example, has become integral to producing lightweight, structurally complex components, typically using titanium or aluminium that can withstand the extreme environments of international flight.

At elevated temperatures, specific metal alloys exhibit a phenomenon known as superplasticity, allowing them to be formed, stretched and elongated into highly intricate shapes without failure or fracture (often improving the material’s strength). This unique capability makes SPF an indispensable process for aerospace applications.

However, the cost and complexity of SPF (including tooling expenses, strict material requirements and long processing times) have largely restricted its use to the aerospace and defence sectors. However, with a degree of innovation, SPF could become a more accessible and attractive option for a wider range of high-value industries, from transport to energy and infrastructure.

The benefits of SPF

The near-net shape manufacturing process is used extensively for aerospace parts and 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 capital-intensive. 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 high-temperature, energy-intensive process has also come under scrutiny, as manufacturers across all industries seek to improve sustainability.

Reducing barriers to entry

To read the rest of this article in the September 2025 issue of ISMR, see https://joom.ag/c52d/p92