Abstract: A manufacturing method is provided during which a plurality of first apertures are formed in a first plate to provide an apertured first plate. The apertured first plate is configured from or otherwise includes first plate metal. A first sheet is bonded to the apertured first plate to form a first grid structure. The first apertures extend through the apertured first plate to the first sheet. The first sheet is configured from or otherwise includes first sheet metal.

Abstract: An assembly is provided for a gas turbine engine. This engine assembly includes an exhaust nozzle extending circumferentially about an axial centerline. The exhaust nozzle extends axially along the axial centerline to a trailing edge. The exhaust nozzle extends radially between an exterior inner surface and an exterior outer surface. The exhaust nozzle includes an inner skin, an outer skin and an internal cavity. The inner skin forms the exterior inner surface and includes a plurality of perforations. The internal cavity is disposed radially between the inner skin and the outer skin. The internal cavity is fluidly coupled with the perforations.

Abstract: A manufacturing method is provided during which a plurality of first apertures are formed in a first plate to provide an apertured first plate. A plurality of second apertures are formed in a second plate to provide an apertured second plate. The apertured first plate and the apertured second plate are bonded to a base sheet to form a structure. The base sheet is bent to form a bend in the structure between the apertured first plate and the apertured second plate.

Abstract: An aircraft propulsion system apparatus includes a first skin, a second skin, an intermediate layer between the first skin and the second skin, a first cellular core and a second cellular core. The first cellular core is connected to the first skin and the intermediate layer. The first cellular core includes a plurality of first core chambers, where a first of the first core chambers is fluidly coupled with one or more first perforations in the first skin and one or more first perforations in the intermediate layer. The second cellular core is connected to the intermediate layer and the second skin. The second cellular core includes a plurality of second core chambers and a plurality of corrugations, where a first of the second core chambers is fluidly coupled with the first of the first core chambers through the one or more first perforations in the intermediate layer.

Abstract: A manufacturing method is provided during which a plurality of first apertures are formed in a first plate to provide an apertured first plate. A plurality of second apertures are formed in a second plate to provide an apertured second plate. The apertured first plate and the apertured second plate are bonded to a base sheet to form a structure. The base sheet is bent to form a bend in the structure between the apertured first plate and the apertured second plate.

Abstract: A manufacturing method is provided during which a plurality of first apertures are formed in a first plate to provide an apertured first plate. The apertured first plate is configured from or otherwise includes first plate metal. A first sheet is bonded to the apertured first plate to form a first grid structure. The first apertures extend through the apertured first plate to the first sheet. The first sheet is configured from or otherwise includes first sheet metal.

Abstract: A manufacturing process is provided that includes arranging a tubular body with a mandrel. The tubular body circumscribes an outer surface of the mandrel and includes a panel and a sheet. The panel includes a porous first skin, a second skin and a cellular core between and connected to the porous first skin and the second skin. The sheet is configured with the second skin to form a pressure vessel. The first skin and the cellular core are located within the pressure vessel. At least a portion of the outer surface comprises an axially convex geometry. The panel is heated. The heated panel is shaped to at least partially conform to the outer surface by pressurizing fluid within the pressure vessel.

Abstract: A liquid interface diffusion bonded composition comprises a metal honeycomb core such as a nickel-alloy honeycomb core and a nickel-alloy facing sheet bonded thereto. The composition and method of this invention are useful in applications where high strength, heat resistant materials are required, such as in aircraft and aerospace-related structures.

Abstract: A liquid interface diffusion bonded composition comprises a metal honeycomb core such as a titanium honeycomb core and a metal facing sheet such as a titanium facing sheet bonded thereto. The composition is prepared by a method comprising: (a) providing a metal honeycomb core having a faying surface and a metal facing sheet having a faying surface; (b) placing together the honeycomb core faying surface and the facing sheet faying surface, and providing therebetween a metal foil typically formed by a rapid solidification process or a melt spinning process, with the metal foil comprising about 10.5-12.5 wt. % zirconium, about 20-24 wt. % copper, about 10.5-16 wt. % nickel, and the balance being titanium; (c) subjecting the faying surfaces and metal foil therebetween to sufficient positive pressure to maintain position and alignment for joining; and (d) heating the faying surfaces and metal foil therebetween in a protective atmosphere to a temperature in the range of 1700-1800 degrees F.