Laser forming of titanium aircraft parts

The feasibility of using laser-forming as an alternative to hot brake forming of small batches of titanium aircraft parts has been investigated. The main advantage that it has over conventional hot brake forming is increased process flexibility. After extensive experimentation was performed, including designed experiments, it was determined that laser forming with an Nd:YAG laser is a controllable, flexible manufacturing process for bending titanium sheet. Unfortunately, the flexibility advantage is overshadowed by the fact that, with respect to forming of titanium aircraft parts, laser forming is significantly slower, more labor- and energy-intensive, and results in unacceptable fatigue and fracture properties at the bend line due to unavoidable microstructural changes. It appears to be best suited for rapid prototyping instead.