Abstract: The invention provides methods of superplastic forming and diffusion bonding and a gas inlet tube that facilitates the methods which produce structures that are substantially mark off free. Methods include disposing a sealed pack into a die having a patterned surface and an opposite surface; applying a first pressure within the die around an outside of the pack; applying a second pressure within the pack, the second pressure exceeding the first pressure; and forming the pack by superplastic deformation into a diffusion-bonded structure. Further, a gas inlet tube is provided having an inner tube and an outer tube, where the outer tube is weldable to the pack in a gas tight seal.

Abstract: A superplastically formed structural assembly is provided, as is an associated preform and method for forming such an assembly. The assembly includes a skin member and a support member that are joined to define a space between the members and between the joints. The assembly can be produced by joining the members in a flat configuration, and then forming the resulting preform to a predetermined shape of the structural assembly. The support member defines at least one aperture in communication with the space between the members. Thus, the skin member can be formed by delivering a pressurized fluid through the support member to the skin member, e.g., to superplastically form the skin member against a die that defines a contour surface corresponding in shape to the predetermined configuration of the assembly. The support member can extend in a substantially direct configuration between opposing portions of the skin member.

Abstract: A superplastically formed structural assembly is provided, as is an associated preform and method for forming such an assembly. The assembly includes a skin member and a support member that are joined to define a space between the members and between the joints. The assembly can be produced by joining the members in a flat configuration, and then forming the resulting preform to a predetermined shape of the structural assembly. The support member defines at least one aperture in communication with the space between the members. Thus, the skin member can be formed by delivering a pressurized fluid through the support member to the skin member, e.g., to superplastically form the skin member against a die that defines a contour surface corresponding in shape to the predetermined configuration of the assembly. The support member can extend in a substantially direct configuration between opposing portions of the skin member.

Abstract: A superplastically formed structural assembly is provided, as is an associated preform and method for forming such an assembly. The assembly includes a skin member and a support member that are joined to define a space between the members and between the joints. The assembly can be produced by joining the members in a flat configuration, and then forming the resulting preform to a predetermined shape of the structural assembly. The support member defines at least one aperture in communication with the space between the members. Thus, the skin member can be formed by delivering a pressurized fluid through the support member to the skin member, e.g., to superplastically form the skin member against a die that defines a contour surface corresponding in shape to the predetermined configuration of the assembly. The support member can extend in a substantially direct configuration between opposing portions of the skin member.

Abstract: A tubular part having a tubular main body and an integral tubular pullout projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material.

Abstract: There is provided an apparatus for handling a structural member. The apparatus includes a beam that extends from a first end to a second end and a shuttle in translational communication with the beam in a direction extending between the first and second ends. A fork actuator is connected to the shuttle and capable of hydraulically raising and lowering a fork. The fork can include a cooling system to maintain a temperature of the fork, even when used in a heated environment.

Abstract: A multisheet structure is made using compression diffusion bonding according to the present invention using a CRES template to apply increased pressure in the areas designated for diffusion bonds (DB) to improve the bond quality and to reduce the processing time. The CRES template is patterned to correspond with the DB arrangement in the superplastically formed part. The forming press forces the template against the pack of SPF sheets to provide 300-1200 psi or more pressure along the bond lines to speed their formation.

Abstract: There is provided an apparatus for handling a structural member. The apparatus includes a beam that extends from a first end to a second end and a shuttle in translational communication with the beam in a direction extending between the first and second ends. A fork actuator is connected to the shuttle and capable of hydraulically raising and lowering a fork. The fork can include a cooling system to maintain a temperature of the fork, even when used in a heated environment.

Abstract: The life of ceramic SPF dies can be enhanced significantly by plasma spray application of a cordierite glaze on the forming surface. The preferred glaze has a coefficient of thermal expansion close to or matching with the ceramic of the die, and, typically, is a 2•2•5 MAS system including 2-10 mol % TiO2 (or above 8 wt %).

Abstract: A tubular part having a tubular main body and an integral tubular pullout projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material.

Abstract: The life of ceramic SPF dies can be enhanced significantly by plasma spray application of a cordierite glaze on the forming surface. The preferred glaze has a coefficient of thermal expansion close to or matching with the ceramic of the die, and, typically, is a 2•2•5 MAS system including 2-10 mol % TiO2 (or above 8 wt %).

Abstract: A tubular part having a tubular main body and an integral tubular pullout projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material.

Abstract: A tubular part having a tubular main body and an integral tubular pullout projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material.

Abstract: A multisheet structure is made using compression diffusion bonding according to the present invention using a CRES template to apply increased pressure in the areas designated for diffusion bonds (DB) to improve the bond quality and to reduce the processing time. The CRES template is patterned to correspond with the DB arrangement in the superplastically formed part. The forming press forces the template against the pack of SPF sheets to provide 300-1200 psi or more pressure along the bond lines to speed their formation.

Abstract: A tubular part having a tubular main body and an integral tubular protrusion projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material.

Abstract: A method of manufacturing traverse ribbed troughs of thermoplastic resin material comprises the following steps. A length of trough is injection molded in a mold cavity between male and female molds, the mold cavity being configured to form integral raised traversing ribs on the outer surface of the trough and a plurality of spaced extensions at an end. The injection molding is cooled to initiate setting of the resin/composition, the male and female molds are disengaged and a partially set resin/composition trough length is ejected. The male and female molds are re-engaged, with extension containing end of the formed trough participating in closing an open end of the mold cavity. Further resin/composition is injected into the cavity which forms a homogeneous continuum with the partially set extension containing end of the trough end which participated in closing, forming a continuing trough length, steps being repeated until the desired length of trough is formed.

Abstract: A reinforced ceramic structure, such as a superplastic forming die for forming a metal part, has a body of cast silica/calcium aluminate or mullite based ceramic material; and a plurality of reinforcing rods, made of monolithic fused oxides of silicon or aluminum, cast into said ceramic body. The rods have a thickness between ⅛″-2.0″ and are spaced apart on centers by about 2-10 times the diameter of the rods. The rods are bonded in the ceramic body or they may be coated with a release agent to prevent bonding to said ceramic body so that they can translate in the direction of their axes to prevent cracking during drying and curing. The rods are disposed in an array of at least two rows, with the rods in each row arranged parallel to each other and with the rods in adjacent rows arranged orthogonally to each other. The rows are spaced apart a distance equal to about ½-3 times the diameter of the rods.

Abstract: Compression diffusion bonding according to the present invention uses a CRES template to apply increased pressure in the areas designated for diffusion bonds (DB) to improved the bond quality and to reduce the processing time. The CRES template is patterned to correspond with the DB arrangement in the superplastically formed part. The forming press forces the template against the pack of SPF sheets to provide 300-1200 psi or more pressure along the bond lines to speed their formation.

Abstract: A superplastic forming system includes a free standing generally block-shaped ceramic monolithic die base having a bottom surface on which the die rests, and a top surface, opposite to the bottom surface, in which a forming cavity is formed and which is surrounded by a contact surface. The forming cavity has a shape like the desired shape of sheet metal parts to be formed by superplastic forming in the die. A die lid having a horizontal cross sectional shape and size approximately equal to the die base, and having a contact surface corresponding in size and contour to the die base contact surface is placed on the base with the contact surfaces aligning and in contact.

Abstract: A method of producing a ceramic die for use in superplastic forming includes designing a free standing generally block-shaped ceramic monolithic die base with a bottom surface on which the die rests, and a top surface, opposite to the bottom surface, in which a forming cavity is located and which is surrounded by a contact surface. The forming cavity is shaped like the desired shape of sheet metal parts to be formed by superplastic forming in the die. A die lid is designed having a horizontal cross sectional shape and size approximately equal to the die base, and having a contact surface corresponding in size and contour to the die base contact surface, so that the lid may be placed on the base with the contact surfaces aligning and in contact.