Superplasticity

In materials science, superplasticity is a state in which solid crystalline material is deformed well beyond its usual breaking point, usually over about 200% during tensile deformation. Such a state is usually achieved at high homologous temperature. Examples of superplastic materials are some fine-grained metals and ceramics. Other non-crystalline materials (amorphous) such as silica glass ("molten glass") and polymers also deform similarly, but are not called superplastic, because they are not crystalline; rather, their deformation is often described as Newtonian fluid. Superplastically deformed material gets thinner in a very uniform manner, rather than forming a "neck" (a local narrowing) that leads to fracture. Also, the formation of microvoids, which is another cause of early fracture, is inhibited.

In metals and ceramics, requirements for it being superplastic include a fine grain size (less than approximately 20 micrometres) and a fine dispersion of thermally stable particles, which act to pin the grain boundaries and maintain the fine grain structure at the high temperatures and existence of two phases required for superplastic deformation. Those materials that meet these parameters must still have a strain rate sensitivity (a measurement of the way the stress on a material reacts to changes in strain rate) of >0.3 to be considered superplastic.

The mechanisms of superplasticity in metals are still under debate—many believe it relies on atomic diffusion and the sliding of grains past each other. Also, when metals are cycled around their phase transformation, internal stresses are produced and superplastic-like behaviour develops. Recently high-temperature superplastic behaviour has also been observed in iron aluminides with coarse grain structures. It is claimed that this is due to recovery and dynamic recrystallization.

The process offers a range of important benefits, from both the design and production angles. To begin with there is the ability to form components with double curvature and smooth contours from single sheet in one operation, with exceptional dimensional accuracy and surface finish, and none of the "spring back" associated with cold forming techniques. Because only single surface tools are employed, lead times are short and prototyping is both rapid and easy, because a range of sheet alloy thicknesses can be tested on the same tool.

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