Titanium, a lightweight yet extremely strong metal, is indispensable in the aerospace industry. However, the forming of the alloy most commonly used (the so-called α-β titanium alloy Ti-6Al-4V) is considered particularly challenging. Conventional processes are energy-intensive and complex – so-called “superplastic forming” (SPF) requires very high temperatures (e.g. 840–930 °C for Ti-6Al-4V) and low forming speeds. Furthermore, prolonged exposure to high temperatures in air can lead to the formation of a brittle, oxygen-rich “α-case” layer, which must subsequently be removed in a labour-intensive process.
A novel hot deep-drawing process has now been developed at the AIT’s LKR Leichtmetallkompetenzzentrum Ranshofen, demonstrating that α-β titanium sheets exhibit excellent deep-drawing properties at temperatures below 500 °C. This is a crucial advantage in practical terms: at these temperatures, conventional hot-work steels can be used as forming tools – instead of the expensive nickel-based alloys that would otherwise be required for significantly higher process temperatures. As isothermal forming at 500 °C or below is not successful, the process relies on preheating the sheet (below the SPF temperature) and subsequent forming in the press. The key advantage over established processes lies in the dramatically reduced forming times, which enable significantly faster cycle times and thus substantially higher productivity.
Energy savings through significantly lower temperatures
The effectiveness of this process has been demonstrated by concrete forming results: as early as 2022, a test component with a depth of 44 mm was successfully formed. Further optimisations enabled a drawing depth of 68.5 mm to be achieved. At the same time, the preheating time, preheating temperature and deep-drawing temperature were further reduced. Tests using Ti-6Al-4V sheets with different surface finishes – supplied by the industry partner voestalpine BÖHLER Bleche GmbH & Co KG – demonstrated excellent reproducibility. It is particularly significant that the process also works with rougher surfaces, thereby reducing the need for grinding.
The material properties also highlight this technological breakthrough: an elongation at break of over ten per cent was achieved without any additional heat treatment following the deep-drawing process. Furthermore, the results suggest that multi-stage forming processes will be possible in future without intermediate heat treatment – initial two-stage trials have already been successful. Another advantage is that no brittle α-case layer is visible on the component surface. This is attributed to the comparatively short exposure to high temperatures. An Austrian patent has already been granted for the process, and an international patent application is pending. This means the innovation is also strategically secured – providing a basis for further establishing titanium forming at moderate temperatures in a resource-efficient manner for industrial applications.
AIT connects science and innovation
The ability to rapidly translate new findings into marketable technologies and practical solutions is increasingly becoming a key competitive factor for Europe. At this interface between science, technology and application, applied research at the AIT Austrian Institute of Technology plays a central role. Austria’s largest research and technology organisation aligns its research closely with the needs of industry and current societal challenges. AIT’s research makes a difference and creates solutions – for businesses, society and, ultimately, for us all.
AIT Impact Report
The AIT Impact Report 2026 uses around 30 examples to illustrate how AIT, together with partners from industry, academia and the public sector, translates research into concrete solutions. The projects presented range from the digitalisation of industrial processes, through resilient infrastructure and sustainable energy and industrial systems, to health, mobility, security and the circular economy.
The AIT Impact Report 2026 is available online (in German): www.ait.ac.at/impact-report
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