Aerospace
Aerospace
HFQ® Technology has the potential to replace aluminium aerospace structures manufacturing methods that have been used for over 50 years, offering significant benefits in conversion cost, material yield (the ‘buy-to-fly’ ratio), dimensional capability and scalability.
With aircraft manufacturers facing the challenges of electrification, sustainable fuels, cost competitiveness and capacity of its supply chain, HFQ® hot forming of aluminium presents a multi-purpose solution for thin gauge airframe and interior structures. HFQ® can be used for 2xxx, 6xxx and 7xxx alloys for fuselage structures, nacelles, lip skins, fairings, wing ribs, seats and many other components with gauges from <1mm through to 4.5mm, depending on the specific alloy.
HFQ Technology Associates have has already engaged in development projects with the leading aircraft manufacturers including Boeing; and has signed up its first manufacturing tier – EMI Aerospace in the USA. It’s solution has been applied for 100% recycled alloys for aerospace seating, securing a prestigious Making The Difference Award from the Aerospace Technologies Institute.
Fast forming, no springback
By forming a complex geometry in a single blow with cycle times potentially at low as 20s for aerospace parts, HFQ® has inherent cost advantages versus long-standing techniques such as superplastic forming, spinning or multi-step cold forming. The absence of springback in HFQ® aluminum hot forming eliminates complicated secondary operations and leads to reduced scrap rates. Moreover, against machining from solid billet less raw material is used, with HFQ® material yields frequently between 55 and 65% versus down to 5% for some machined structures.
Against composites, particularly for aircraft seating, aluminium offers a much lower material cost and processing time, whilst being almost the same weight, if the design is optimised for the HFQ® process. Other advantages include the ease of joining versus carbon fibre assemblies and the inherent consistency of aluminium alloy properties (whereas carbon fibre components do often suffer from variable quality and high defect rates). HFQ® parts will require investment in a press tool, which can be amortised over the part production lifetime; or for certain designs, the tool can be made in modular layout, permitting use over a range of geometries or applications.
Highly scalable
Through the adaptation of an aluminium hot forming process pioneered in the high volume and cost-conscious automotive sector, aerospace companies can exploit an HFQ® process that offers part integration and high scalability. Part consolidation by effective design with our applications specialists, can reduce design and qualification time and simplify the supply chain. The short cycle time means that even a lightly-automated HFQ® aluminium hot forming line could produce in excess of 100,000 components a year. Because of these scalability advantages, HFQ® is being considered for next generation aircraft and as a solution for the planned ramp up in aircraft production.
Learn more …
You can explore real-world examples of HFQ® Technology in action with our curated collection of case studies. Discover how leading aerospace manufacturers have leveraged HFQ® to overcome challenges, optimise performance, and push the boundaries of innovation in aircraft design and manufacturing. From structural components to interiors, these case studies showcase the versatility and impact of HFQ® Technology for aluminium.
HFQ® Applications Collection | Videos
HFQ® Solutions for the Aerospace Industry
Impression Technologies’ Product Manager Ed Cooper, discusses the vital role that the company’s HFQ® Technology plays in the aviation industry, and how such innovations have become a crucial enabler for a circular economy.
HFQ® Applications Collection | Videos
HFQ® Lightweight Armrest
This is an ultra-light weight, high strength HFQ® armrest in 7075 alloy for aircraft seats, that offers significant savings in production cost and material utilisation.
Case Studies
