Abstract: There are provided an apparatus and an associated method for manufacturing superplastically formed structural assemblies from preforms. The apparatus includes first and second co-operable dies structured to define a die cavity therebetween for at least partially receiving the preform, at least one heater in thermal communication with the die cavity for heating the preform to a forming temperature, and at least one injector in fluid communication with the die cavity. The injector is structured for injecting pressurized gas into the die cavity to urge the preform against one of the dies to form the preform into the structural assembly. Further, at least one of the injectors is structured for injecting a quenchant into the die cavity to thereby heat treat the structural assembly while distortion of the structural assembly is being at least partially restrained by at least one of the dies.

Abstract: There are provided an apparatus and an associated method for manufacturing superplastically formed structural assemblies from preforms. The apparatus includes first and second co-operable dies structured to define a die cavity therebetween for at least partially receiving the preform, at least one heater in thermal communication with the die cavity for heating the preform to a forming temperature, and at least one injector in fluid communication with the die cavity. The injector is structured for injecting pressurized gas into the die cavity to urge the preform against one of the dies to form the preform into the structural assembly. Further, at least one of the injectors is structured for injecting a quenchant into the die cavity to thereby heat treat the structural assembly while distortion of the structural assembly is being at least partially restrained by at least one of the dies.

Abstract: Apparatus and methods for single sheet forming using induction heating include a pair of dies defining a die cavity for containing a workpiece, which is inductively heated by an oscillating magnetic field within the die cavity. A susceptor is positioned between the workpiece and one die surface defined by one of the dies. The susceptor is capable of coupling with the oscillating magnetic field to induce a current within the susceptor to heat the susceptor. The susceptor transfers heat to the workpiece. An inlet for pressurized forming fluid injects the fluid between the susceptor and the workpiece to form the workpiece into direct contact with a forming surface defined by one of the dies. The susceptor may be electrically connected to the workpiece to inhibit electrical arcing from the susceptor to adjacent electrically conductive components when current is induced in the susceptor.

Abstract: There are provided an apparatus and an associated method for manufacturing superplastically formed structural assemblies from preforms. The apparatus includes first and second co-operable dies structured to define a die cavity therebetween for at least partially receiving the preform, at least one heater in thermal communication with the die cavity for heating the preform to a forming temperature, and at least one injector in fluid communication with the die cavity. The injector is structured for injecting pressurized gas into the die cavity to urge the preform against one of the dies to form the preform into the structural assembly. Further, at least one of the injectors is structured for injecting a quenchant into the die cavity to thereby heat treat the structural assembly while distortion of the structural assembly is being at least partially restrained by at least one of the dies.

Abstract: A die liner for use in a die having a die body wherein the die body is configured to form a workpiece. The die liner is a discrete structure that is configured to be used in conjunction with the die body. The die liner defines a forming surface for forming the workpiece and is configured to have at least one characteristic that is different than a corresponding characteristic of the die body such that the die liner increases the durability of the die.

Abstract: Apparatus and methods for single sheet forming using induction heating include a pair of dies defining a die cavity for containing a workpiece, which is inductively heated by an oscillating magnetic field within the die cavity. A susceptor is positioned between the workpiece and one die surface defined by one of the dies. The susceptor is capable of coupling with the oscillating magnetic field to induce a current within the susceptor to heat the susceptor. The susceptor transfers heat to the workpiece. An inlet for pressurized forming fluid injects the fluid between the susceptor and the workpiece to form the workpiece into direct contact with a forming surface defined by one of the dies. The susceptor may be electrically connected to the workpiece to inhibit electrical arcing from the susceptor to adjacent electrically conductive components when current is induced in the susceptor.

Abstract: An apparatus and method for heat treating a structural member, for example, to relieve stresses therein, are provided. The structural member is restrained in a die cavity by one or more inflatable bladders so that a desired dimensional accuracy is achieved. The structural member can be heated by an electromagnetic field generator, such as an induction coil, that heats one or more susceptors to a characteristic Curie temperature. The apparatus can be used to process structural members of various sizes and shapes, and the heating and cooling cycle can be performed relatively quickly.

Abstract: There are provided an apparatus and an associated method for manufacturing superplastically formed structural assemblies from preforms. The apparatus includes first and second co-operable dies structured to define a die cavity therebetween for at least partially receiving the preform, at least one heater in thermal communication with the die cavity for heating the preform to a forming temperature, and at least one injector in fluid communication with the die cavity. The injector is structured for injecting pressurized gas into the die cavity to urge the preform against one of the dies to form the preform into the structural assembly. Further, at least one of the injectors is structured for injecting a quenchant into the die cavity to thereby heat treat the structural assembly while distortion of the structural assembly is being at least partially restrained by at least one of the dies.

Abstract: A die liner for use in a die having a die body wherein the die body is configured to form a workpiece. The die liner is a discrete structure that is configured to be used in conjunction with the die body. The die liner defines a forming surface for forming the workpiece and is configured to have at least one characteristic that is different than a corresponding characteristic of the die body such that the die liner increases the durability of the die.

Abstract: An induction heating device for manufacturing a part by heating the part to a predetermined temperature. The induction heating device includes an induction coil connected to an electrical power supply for generating an electromagnetic flux field. A smart susceptor of the heating device is positioned in the electromagnetic flux field and includes a magnetically permeable material supported by a mesh structure. The magnetically permeable material generates heat in response to the flux field. The mesh structure provides support for the magnetically permeable material and closely conforms to the desired outer geometry of the part. The magnetically permeable material may be applied as a powder to the mesh using a hot spray gun, allowing tight conformance of the susceptor to the part geometry while avoiding forming limits of sheet metal susceptors.

Abstract: A superplastically formed, diffusion bonded sandwich structure having integral metal hardpoints, made by joining two superplastic metal core sheets together into a core pack by welding or diffusion bonding along a pattern of lines which form junction lines between the core sheets when the pack is inflated by gas pressure at superplastic temperatures. Face sheets are laid under and over the core pack and metal inserts are interposed between the face sheets and the core. All of the sheets in the pack are sealed together around an outside peripheral edge to create a gas tight envelope. The pack is heated to superplastic temperatures in a cavity in a die, and the top and bottom face sheets are diffusion bonded to top and bottom surfaces of the metal insert by application of heat and pressure from top and bottom inner surfaces of the die cavity.

Abstract: A holder 20 for supporting loop-handled plastic bags 500 includes a support structure 22, two oppositely positioned cleats 28 and 30 for accepting the loop handles 506, and at least two oppositely positioned downwardly projecting fingers 36 and 40 for downwardly engaging the side portions 508 and 510 of the plastic bags 500 and thereby holding the plastic bags 500 in an open state suitable for receiving deposited items. In a preferred embodiment, cleats 28 and 30 and downwardly projecting fingers 36 and 40 are permanently connected to the mouth 26 of a wastebasket-type container 22. In an alternative embodiment, cleats 128 and 130 and downwardly projecting fingers 136 and 140 are removably connected to container mouth 126 with clips 129 and 150, and are selectively positionable along the mouth 126.

Abstract: A gas management system for delivering forming gas under a controlled pressure through a first portion of a piping network to a region of a forming die between a die lid and a blank to be formed in a superplastic forming machine includes a gas pressure regulator in the piping network and two control loops. The first control loop has a first pressure transducer communicating with the piping network downstream of the gas pressure regulator and operatively with the gas pressure regulator. The second control loop includes a pulse controller downstream of the first pressure transducer and a second pressure transducer communicating with the piping network downstream of the pulse controller and operatively with the pulse controller. The gas pressure regulator receives signals from a controller to adjust the pressure at which the gas pressure regulator opens to release gas through the pressure regulator.

Abstract: A method is set forth of forming a hollow structure having a varying mass distribution. Two sheets of a diffusion bondable and superplastic formable material are formed with one flat surface and an opposite surface contoured to have a selected mass distribution. A stop-off material is applied between selected non-peripheral portions of each of the flat surfaces whereat diffusion bonding is to be prevented and superplastic forming is to be required. An intermediate flat core sheet may also be present. The flat surfaces are positioned in abutting relation to each other or to the intermediate flat core sheet. The sheets are subjected to diffusion bonding conditions. The sheets are superplastically formed to expand them apart against a die. The invention also provides a method of preinflating contoured sheets prior to superplastically forming them to avoid truss core rupture. Hollow aircraft engine components are formed by the methods.