Application of Ceramic Film as Means of Lubrication for Forming of Ti Sheet in a Highly Localized Deformation Process

Abstract

Incremental forming is a novel die-less sheet forming process. There is a need for special means to retain lubricant at the tool/sheet interface during forming. To fulfill the stated aim, a porous ceramic film was developed on pure Ti substrate, and it was done through an electrochemical depsition process known as plasma electrolytic oxidation. The film with preferred pore size could be realized after several attempts by varying the processing parameters. In order to characterize the film, a variety of tests including microstructure, film-substrate bond strength and tribological properties tests were conducted. On-job performance of the film was also examined by forming Ti components employing a range of forming conditions. It was found that the proposed method of lubrication was effective, and the plasma eletrolytic oxidation process can be employed to fabricate films on pure Ti sheet to provide means of lubrication during incremental forming.