Axial-load bulge forming

Axial-load bulge forming is the most advanced technology for producing sheet metal components from superalloy materials. Voss bulge forming presses help maintain uniform wall thickness in materials up to 0.100 inch thick. Bulge-formed components can currently be produced up to 24 inches long and 24 inches in diameter– and larger capacity presses are being added. Intricate parts as small as 1/4-inch diameter and 0.008 inch material thickness can also be bulge formed.

Axial-load bulge forming capability was initially established to produce sheet metal flanges for pneumatic ducting systems. Capability has subsequently been expanded to facilitate more effective production of parts with complex shapes that previously had been formed by spinning, hydroforming or drop hammering.

Capabilities:

Metals:

Parts can be formed in a wide variety of materials, including aluminum, 300 series stainless steels, titanium, 17-4 PH stainless steel,
nickel alloys 625 and 718, and other high-temperature alloys.

Sizes:

Material thickness can vary from approximately 0.008 inch to 0.100 inch. Current production equipment can produce parts as large
as 24 inches in diameter and 24 inches in height. Larger sizes may be produced with special and/or modified tooling setups.

Advantages:

Minimal wall thinning occurs with axial-load bulge forming since metal is "fed in" to compensate for shape expansion. Parts previously produced by welding together separate components can now be formed as a single part.

Voss designed and built axial-load bulge forming presses are used to produce a wide variety of both symmetrical and nonsymmetrical products, some are shown here.

Bulge forming capabilities enable Voss to produce one piece wyes and tees that are used on cooling tubes on aircraft turbine engines.