Developments and perspectives on the precision forming processes for ultra-large size integrated components

Abstract In order to meet the requirements of high reliability, long-lifetime and lightweight in a new generation of aerospace, aviation, high-speed train, and energy power equipment, integrated components are urgently needed to replace traditional multi-piece, welded components. The applications of integrated components involve in a series of large-size, complex-shaped, high-performance components made of difficult-to-deform materials, which present a huge challenge for forming ultra-large size integrated components. In this paper, the developments and perspectives of several extreme forming technologies are reviewed, including the sheet hydroforming of ultra-large curved components, dieless hydroforming of ellipsoidal shells, radial-axial ring rolling of rings, in situ manufacturing process of flanges, and local isothermal forging of titanium alloy components. The principle and processes for controlling deformation are briefly illustrated. The forming of typical ultra-large size integrated components and industrial applications are introduced, such as the high strength aluminum alloy, 3 m in diameter, integrated tank dome first formed by using a sheet blank with a thickness the same as the final component, and a 16 m diameter, integrated steel ring rolled by using a single billet. The trends for extreme forming of ultra-large size integrated components are discussed with a goal of providing ideas and fundamental guidance for the further development of new forming processes for extreme-size integrated components in the future.