Servizi di Formatura e Produzione Pesante del Titanio
Formatura e produzione pesante del titanio: laminazione a caldo di lamiere, forgiatura a stampo aperto/chiuso, assemblaggio su larga scala. Capacità 12,000 x 4,500 x 4,000 mm, formatura a caldo 50+ mm, gru da 30 ton, AS9100D.
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Forming & Heavy Spettro di Processo
Three heavy fabrication workflows covering the full spectrum — from hot rolling of thick plate to closed-die forging and multi-component assembly of large-scale titanium structures.
Heavy Titanium Plate Rolling
Heavy Plate Rolling for Pressure Vessels & Reactor Shellsservices.heavyprocessspectrum.card1.description
- Hot rolling of heavy titanium plate (6-50 mm thickness) on 3-roll hydraulic bending rolls
- Cylindrical shell rolling for pressure vessels, reactors, and large-diameter pipe sections
- Multi-pass rolling sequences with intermediate stress-relief annealing to prevent spring-back
- Dimensional verification via laser scanning — ovality within ±0.5% of diameter on rolled shells
Monolithic Heavy Structural Forging
Closed-Die & Open-Die Forging for Large Componentsservices.heavyprocessspectrum.card2.description
- Closed-die forging of structural nodes, flanges, and heavy fittings
- Open-die upsetting and drawing for large shaft and bar stock
- Ring rolling for seamless flanges and bearing races
- Post-forge heat treatment: annealing, solution treat & age, stress relief
Large-Scale Multi-Component Integration
Full-Scale Assembly & Gas-Shielded Weldingservices.heavyprocessspectrum.card3.description
- Multi-meter structural frame welding and assembly
- Mechanized GTAW/GMAW for long-seam heavy plate welding
- Heavy shaft and agitator fabrication with full NDT verification
- Pre-assembly fit-up and dimensional verification on surface plates
Heavy Manufacturing Dashboard della Capacità
Colossal machinery tonnage, dimensional bounds, and metrology metrics of our heavy titanium forming and forging facility.
Max Fabricated Footprint
Massive structural profile capacity accommodating multi-meter infrastructure frames, pressure vessel shells, and subsea structures in a single integrated build envelope.
Maximum Gauge Capacity
In-house hot forming capability coping with heavy titanium stocks exceeding 50 mm thick — using localized infrared heating to enhance ductility before bending or rolling.
Total Cranes Lifting Load
Heavy duty bay crane transport layout scaling up to 30 metric tons — enabling safe handling and positioning of massive forged blocks, rolled shells, and assembled structures.
Volumetric NDT Inspection
100% compliant under Class I Radiographic (X-Ray) and Ultrasonic (UT) zero-defect requirements — ensuring structural integrity validation on every weld and parent metal section.
NDT methods include radiographic (RT) per ASME Section V, ultrasonic (UT) per ASTM E2375, and dye-penetrant (PT) per ASTM E1417. All hot forming performed in inert atmosphere.
Hot Forming & Stress Competenza nella Distensione
Conquering heavy titanium spring-back and structural warp requires thermal-mechanical modeling and full-scale vacuum stress relief. Here's how we achieve dimensional stability on multi-ton structures.
Thermal Forming & Spring-Back Micro-Compensation
Titanium's high strength-to-modulus ratio (UTS 950 MPa vs. elastic modulus 114 GPa) causes extreme spring-back during cold forming — where the material elastically recovers 15-30% of the bend angle after the forming load is released. On thick plates (10-50 mm), this spring-back is highly nonlinear and geometry-dependent, making conventional over-bend allowances inaccurate and causing costly dimensional rework.
Localized Infrared Heating (600-800°C) & Finite Element Spring-Back Modeling
- Localized infrared heating arrays target the bend zone exclusively, raising the titanium temperature to 600-800°C — reducing yield strength by 60-70% and enabling tight-radius forming without cracking
- Finite Element Analysis (FEA) spring-back prediction models simulate the complete forming cycle — accounting for temperature-dependent elastic modulus, strain-rate sensitivity, and anisotropic material behavior specific to each titanium grade
- Iterative over-bend compensation: the FEA model's predicted spring-back angle is fed into the press brake controller, adding 2-5° of over-bend to the programmed angle — achieving final formed angles within ±0.5° after cooling
- Result: ±0.5° angular accuracy on hot-formed heavy titanium plates up to 25 mm thick — no cracking, no spring-back rework, no secondary forming operations
Full-Scale Vacuum Stress-Relief Thermal Cycles
Heavy titanium plate rolling, forging, and welding operations introduce massive residual stresses — from the non-uniform plastic deformation during forming (rolling stresses up to 60% of yield), thermal contraction stresses in multi-pass weld seams, and stress concentration at formed radius transitions. If not relieved, these locked-in stresses cause delayed distortion during machining, dimensional drift over time, and unpredictable performance under deep-sea hyperbaric or cyclic fatigue loading.
Multi-Meter Computerized Vacuum Annealing Furnace — 95%+ Stress Elimination
- Computer-controlled vacuum furnace with programmable heating rates (50-150°C/hr) and soak temperatures (540-760°C depending on titanium grade) — ensuring uniform thermal distribution across the entire structure with ±5°C temperature uniformity
- Vacuum atmosphere maintained at ≤10⁻⁵ mbar throughout the entire annealing cycle — preventing any surface oxidation or alpha-case formation on the titanium component during the multi-hour stress relief process
- Controlled slow cooling (furnace cool at ≤100°C/hr to below 300°C) before opening — preventing re-introduction of thermal stresses that would occur from rapid air cooling and maintaining the stress-relieved state achieved during the soak phase
- Post-stress relief dimensional verification via laser tracker and CMM — confirming that distortion is within ±0.5 mm/m before any secondary machining operations begin, eliminating costly mid-process corrections
Have a Multi-Ton Structural Program?
Carica la Tua BOM per la Conformità Pesante e il Preventivo su Misura
Upload your complete BOM packages, structural drawings, and technical specifications for an optimized 24-hour heavy compliance assessment — including hot forming feasibility, forging grain flow analysis, vacuum stress relief cycle planning, NDT protocol development, and scaled multi-tier pricing for prototype through production volumes.
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