To develop a new SPF process using tailored blank technique, a series of forming experiments were carried out on high strength aluminum alloy 7475 SPF grade sheets. Some rectangular blank sheets, with a butt weld line at each longitudinal center, were prepared using friction stir welding (FSW) under several conditions. The blank sheets were experimentally formed into a slender pan with rectangular section, for intended reduction of thickness in half approximately, provided the forming was successful. Some blank sheets were formed successfully with decreased thickness on the joined line along with the reduction on the base metal. Breakage in base metal was seen on tensile test pieces, including joined line after the forming. And it was found that a drastic change of grain size caused by superplastic forming, from 1000 μm to 5 μm, happened in some conditions of FSW. As a result, the relationship between the superplastic formability of the joined line and the conditions of FSW was analyzed, and the possibility in the practical application of the new process was verified for 7475 aluminum alloy.
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