Ti2AlNb Sheet Pulse Current-Assisted Flexible Granular Medium Forming of Box-Shaped Components

Pulse current-assisted flexible granular medium forming is a promising approach for manufacturing complex thin-walled components from difficult-to-deform Ti2AlNb-based alloys. In this study, the electro-thermo-mechanical deformation behavior of Ti2AlNb sheets is investigated through pulse current-assisted uniaxial tensile tests, microstructural characterization, and finite element simulations. The influences of pulse current intensity and strain rate on flow behavior, fracture characteristics, and phase evolution are clarified, and an effective forming window is identified. Numerical simulations are employed to analyze the role of granular medium friction in material flow and wall thickness distribution, providing guidance for forming box-shaped components. The results demonstrate that forming at approximately 950 °C with a strain rate of 0.001 s−1 reduces deformation resistance, while enhanced tangential interaction between the granular medium and the sheet improves wall thickness uniformity. This study provides a feasible processing route and practical guidelines for the fabrication of complex Ti2AlNb sheet components.