Modeling the Forming in the Superplastic State Using Tin- and Lead-Based Alloys: Occupational Safety Aspects

Processing titanium alloys such as VT23 in the superplasticity forming mode is a key technology in the aerospace industry. At the same time, it is associated with high risks for personnel. The processing temperature reaches 900 °C, which requires using heat-resistant equipment, powerful ventilation systems, and protection against toxic emissions. These factors hamper experiments, especially in conditions of educational labs with limited resources. The solution for the problem is the use of low-temperature model alloys such as POS61 (tin-lead alloy) and Wood’s alloy that imitate the titanium behavior during the superplastic formation, but in safe conditions. The goal of the research has been to evaluate the efficiency of these materials in order to reduce occupational risks and streamline modeling processes. POS61 alloy that demonstrate superplasticity at 100–150 °C, and Wood’s alloy with excessive plasticity, have been used as modeling materials. For the comparison, VT23 titanium alloy processed at 700–900 °C has been used. Research methods have included mathematical modeling of formation processes of a box body via the finite element method and stretch tests at deformation rates of 0.001–0.004 s–¹. The modeling results have shown that forming a 1 mm thick part of POS61 and a 2 mm thick part of titanium ВТ23 causes a similar distribution of deformations. The smallest thickness upon processing has been 0.38 mm for POS61 and 0.34 mm for VT23, which confirms the adequacy of the modeling material. Stretch tests have detected that under temperatures within 100–150 °C, POS61 obtains strength properties similar to titanium, whereas Wood’s alloy, despite its high plasticity, proved to be inapplicable for precise modeling due to its low strength. Using POS61 opens up new opportunities to optimize technologies in aerospace mechanical engineering, reducing the dependence on expensive equipment and increasing occupational safety. Implementing these solutions not only facilitates the protection of employees’ health but also accelerates the implementation of innovative methods of material processing.