Abstract: We combine superplastic forming (SPF) with adhesive bonding (AB) to produce quality multisheet sandwich panel structures, especially those using a superplastic aluminum alloy, such as A1 2004, A1 8090, or A1 1570. We produce the parts with improved energy efficiency and at lower cost. We heat the multisheet pack having an adhesive, preferably a polyimide, between the core sheets and the face sheets to its superplastic forming range. Then, we superplastically form the pack to define adhesive bonds between the sheets in the core and between the core and the face sheets with the flowing adhesive. Finally, we cool the formed pack below the superplastic range to set the adhesive.

Abstract: We combine superplastic forming (SPF) with adhesive bonding (AB) to produce quality multisheet sandwich panel structures, especially those using a superplastic aluminum alloy, such as Al 2004, Al 8090, or Al 1570. We produce the parts with improved energy efficiency and at lower cost. We heat the multisheet pack having an adhesive, preferably a polyimide, between the core sheets and the face sheets to its superplastic forming range. Then, we superplastically form the pack to define adhesive bonds between the sheets in the core and between the core and the face sheets with the flowing adhesive. Finally, we cool the formed pack below the superplastic range to set the adhesive.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can from under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.

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: We combine superplastic forming (SPF) with adhesive bonding (AB) to produce quality multisheet sandwich panel structures, especially those using a superplastic aluminum alloy, such as A1 2004, A1 8090, or A1 1570. We produce the parts with improved energy efficiency and at lower cost. We heat the multisheet pack having an adhesive, preferably a polyimide, between the core sheets and the face sheets to its superplastic forming range. Then, we superplastically form the pack to define adhesive bonds between the sheets in the core and between the core and the face sheets with the flowing adhesive. Finally, we cool the formed pack below the superplastic range to set the adhesive.

Abstract: We combine superplastic forming (SPF) with adhesive bonding (AB) to produce quality multisheet sandwich panel structures, especially those using a superplastic aluminum alloy, such as Al 2004, Al 8090, or Al 1570. We produce the parts with improved energy efficiency and at lower cost. We heat the multisheet pack having an adhesive, preferably a polyimide, between the core sheets and the face sheets to its superplastic forming range. Then, we superplastically form the pack to define adhesive bonds between the sheets in the core and between the core and the face sheets with the flowing adhesive. Finally, we cool the formed pack below the superplastic range to set the adhesive.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack and the two metal face sheets having superplastic characteristics are each chemically cleaned, and the face sheets are placed over and under the core pack.

Abstract: A method to superplastic form sandwich structures is provided. A series of worksheets are joined together at selected locations through the use of partial penetration welding. The worksheets are subsequently superplastic formed in order to form a sandwich structure. The method allows a different number of worksheets to be used at different points throughout the sandwich structure. This results in a sandwich structure with a different internal reinforcement at different locations in the sandwich structure. In the preferred embodiment, a wing is fabricated from a series of worksheets partial penetration welded together using a laser. The worksheets are superplastic formed to producing a wing with a different internal reinforcement at two or more locations in the wing. The wing includes a pair of double thickness skins that define a major portion of aerodynamically smooth outer surface of the airfoil.

Abstract: A method to superplastic form sandwich structures is provided. A series of worksheets are joined together at selected locations through the use of partial penetration welding. The worksheets are subsequently superplastic formed in order to form a sandwich structure. The method allows a different number of worksheets to be used at different points throughout the sandwich structure. This results in a sandwich structure with a different internal reinforcement at different locations in the sandwich structure. In the preferred embodiment, a wing is fabricated from a series of worksheets partial penetration welded together using a laser. The worksheets are superplastic formed to producing a wing with a different internal reinforcement at two or more locations in the wing.

Abstract: A method to superplastic form sandwich structures is provided. A series of worksheets are joined together at selected locations through the use of partial penetration welding. The worksheets are subsequently superplastic formed in order to form a sandwich structure. The method allows a different number of worksheets to be used at different points throughout the sandwich structure. This results in a sandwich structure with a different internal reinforcement at different locations in the sandwich structure. In the preferred embodiment, a wing is fabricated from a series of worksheets partial penetration welded together using a laser. The worksheets are superplastic formed to producing a wing with a different internal reinforcement at two or more locations in the wing.