Abstract: A method of constructing, assembling and disassembling a mandrel for fabricating a monolithic composite nacelle panel for use on an airplane comprises attaching a first fairing bar including an exposed ball roller assembly to a tilting plate; attaching a first outer section to said first fairing bar; attaching a second outer section to said first fairing bar; attaching a center section to said first outer section and said second outer section; attaching a nozzle section to said first fairing bar and positioned adjacent an inner wall of said first outer section, an inner wall of said center section, and an inner wall of said second outer section; attaching a second fairing bar to said first outer section, said center section, and said second outer section; and attaching a cavity section to said second fairing bar.

Abstract: A mandrel is disclosed for fabricating a monolithic composite nacelle panel for use on an airplane. Also disclosed is the method of constructing the mandrel, the method of assembling the mandrel, and the method of disassembling the mandrel.

Abstract: A method of constructing, assembling and disassembling a mandrel for fabricating a monolithic composite nacelle panel for use on an airplane comprises attaching a first fairing bar including an exposed ball roller assembly to a tilting plate; attaching a first outer section to said first fairing bar; attaching a second outer section to said first fairing bar; attaching a center section to said first outer section and said second outer section; attaching a nozzle section to said first fairing bar and positioned adjacent an inner wall of said first outer section, an inner wall of said center section, and an inner wall of said second outer section; attaching a second fairing bar to said first outer section, said center section, and said second outer section; and attaching a cavity section to said second fairing bar.

Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.

Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.

Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.

Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.