In this paper, hot gas pressure forming (HGPF) of Ti-55 high temperature titanium alloy was studied. The hot deformation behavior was studied by uniaxial tensile tests at temperatures ranging from 750 to 900 °C with strain rates ranging from 0.001 to 0.05 s−1
, and the microstructure evolution during tensile tests was characterized by electron backscatter diffraction. Finite element (FE) simulation of HGPF was carried out to study the effect of axial feeding on thickness distribution. Forming tests were performed to validate this process for Ti-55 alloy. Results show that when the temperature was higher than 750 °C, the elongation was large enough for HGPF of Ti-55 alloy. Dynamic recrystallization (DRX) occurred during the tensile deformation, which could refine the microstructure. The thickness uniformity of the formed part could be improved by increasing feeding length. The maximum thinning ratio decreased from 27.7% to 11.5% with the feeding length increasing from 0 to 20 mm. A qualified Ti-55 alloy component was successfully formed at 850 °C, the microstructure was slightly refined after forming, and the average post-form yield strength and peak strength were increased by 8.7% and 6.9%, respectively. Pre-heat treatment at 950 °C before HGPF could obtain Ti-55 alloy tubular component with bimodal microstructure and further improve the post-form strength.
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