Forming 2024 Aluminum

[Datech]

Im trying to form a corrogated repair.Material is .016 2024.With T3 it wrinkle's and cracks.With O im concerned with warping.Section is rather large.Any ideas?

 

[aviat]

Could you please provide more information? Is the repair going on a certified aircraft, what type of aircraft, is it for a control surface, how are you trying to corrugate the metal?

 

[Datech]

The piece is bonded to the inside of an access panel.It's for military use. I machined steel dies and using a 50 ton press.

 

[aviat]

Most of the times that I have dealt with corrugated sheet I ordered a replacement from OEM, but some of it is getting harder to find. It was probably made in the O condition, because manufactures usually form in that condition, then heat-treat to T3 or whatever. I found the site below and they make control surface for the Beaver out of 0.016 material. Maybe it you contacted them they will tell you in what condition the metal is when they form it.

http://www.greeleynet.com/~wordwork/airpage.htm

 

[aviat]

A couple of other things to consider are your radius on your dies or bend allowance. The rule-of-thumb for minimum BA for 2024 O is 1t and for T3 it is 3t. If there is not radius the metal will crack. Also the clearance between dies is important. Finally if you are not already doing so, I think you should consider using a lubricant.

 

[chirgy]

Bending across the grain of the material should help.

 

[Datech]

Thanks for your help. I ended up using O material.The T3 was cracking.