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In some applications, in this case an aluminium box in a subatomic particle detector containing highly sensitive detecting devices, it is important that a formed sheet should show no gas leak from one side to the other. In order to prevent a trial-and-error procedure to make this leak tight box, a method is set up to predict if a formed sheet conforms to the maximum leak constraint. The technique of superplastic forming (SPF) is used in order to attain very high plastic strains before failure. Since only a few of these boxes are needed, this makes, this generally slow, process an attractive production method. To predict the gas leak of a superplastically formed aluminium sheet in an accurate way, finite element simulations are used in combination with a user-defined material model. This constitutive model couples the leak rate with the void volume fraction. This void volume fraction is then dependent on both the equivalent plastic strain and the applied hydrostatic pressure during the bulge process (backpressure).

Prediction of Gas Leak Tightness of Superplastically Formed Products