Innovative manufacturing research on forming of large light armor alloy sections resistant to blast and penetration

Based on the successful demonstration of induction-assisted bending for near-net shape forming of titanium alloys, AEM will work in Phase 2 to extend the concept to other common armor materials. The success of the process derives from the ability to heat a narrow band of material to a point at which its formability increases without metallurgical damage. Metallurgical examination and measurements with the Gleeble Thermo Mechanical Simulator helped validate the induction heating concept for Ti-6Al-4V alloys, nearly doubling the ductility and permitting significantly tighter bend radii than could be achieved previously. The work in Phase 2 will extend this methodology to examine induction-assisted bending of other armor materials (steel and aluminum). The performance of sections formed by bending will be compared with representative welds to ensure a balanced process comparison. Based on the results obtained for additional materials, the project team will assess the need and potential for using the process for post-bend heat treatment. Phase 2 will culminate with the bending of full thickness plate and design of a second generation system that captures Army and industrial requirements. Pending a successful outcome in Phase 2, the second generation system could be built with additional government and industrial support.