Superplastic forming is a high temperature deformation process where neck free elongations of over 400% at low applied stress, half the melting point and low strain rate of about 10-5 to 10-3 s-1are formed. Diffusion bonding is a solid state bonding process capable of joining wide range of metals. A particular evolution of SPF/DB in the last two decades in the aircraft manufacturing has fulfilled the forming process that transform to many complicated parts. During recent years SPF/DB is applied in fabricating complex parts has increased in the automobile and aircraft industry. The purpose of this research work is to analyze the formability of hemispherical bonded shaped part, reduced cost, weight and tooling. This work focuses on forming and bonding two sheets of different thickness using SPF/DB process for a hemispherical shape under controlled conditions. The controlled parameters were forming time, temperature and applied pressure. The experimental study was carried out for different combinations of pressure, temperature and time and the forming height and bonding thickness were observed. A continuous trial by varying the parameters, uniform bonding and complete hemispherical forming was achieved by appropriate pressure, temperature and time. The responses such as forming height and bonding thickness were analyzed.
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