Abstract: In one aspect, the present invention is a web-based system that facilitates rapid and reliable documenting, cataloging, and distributing of proven error proofing techniques. More specifically, and in an exemplary embodiment, a system includes a plurality of clients coupled to a web-based server. Each client includes a plurality of user interface classes and at least one class that provides access to a database. The server includes a plurality of servlets, and at least some of said servlets provide at least one of a database and server access capability to each client. The system further includes a database having a plurality of tables, and at least one of said tables includes at least one error proofing example. The database is accessed by each client via the server.

Abstract: A method is provided for making a two-piece hollow airfoil having a complex geometry. Two metal sheets are formed into initial shapes so as to have a mean camber and twist. A series of raised ribs is machined onto the external side of each of the two sheets. The two sheets are joined together and sealed to form an in-process assembly. The assembly is subjected to high temperature and pressure to diffusion bond the sheets together at selected points. The assembly then subjected to internal pressure at high temperature in order to inflate and superplastically deform the assembly to the desired shape. Excess material is machined off after the inflation step.

Abstract: A method is provided for making a four-piece hollow airfoil. Four metal sheets are preformed into initial shapes. The sheets are sealed together into two pairs or sub-assemblies. Internal cavities are formed in one sheet from each pair prior to sealing. Each sub-assembly is subjected to high temperature and pressure in order to diffusion bond the sheets together at selected points. The cavities of each sub-assembly are then subjected to internal pressure in order to inflate and superplastically deform the sub-assemblies. The inflated sub-assemblies are combined to form a single assembly and the cavities are again subjected to internal pressure in order to bond the sub-assemblies together. The assembly is then exposed to hot isostatic pressing, after which, excess material is machined off.

Abstract: A method for forming a hollow, internally-ribbed airfoil having a complex geometry. The process forms airfoil halves from alloy members in essentially final machined form. The airfoil halves optionally include a gasket around their periphery and optionally, a gasket around the internal sequence of ribs and cavities. Because the airfoil halves are in final form before joining, important interior airfoil dimensions such as skin thickness, cavity size, rib location and gasket location as well as exterior dimensions such as camber and twist may be verified prior to joining. The airfoil halves are then joined by welding, thereby sealing their interiors and diffusion bonding at relatively low pressures. The gaskets eliminate the use of high pressures and associated skin buckling and permit a concentration of the loads at key locations despite the low pressures. After diffusion bonding, any voids are removed by hot isostatically pressing the airfoil in the superplastic temperature range of the alloy.

Abstract: A method for making a three-piece hollow airfoil includes preforming three metal sheets into initial shapes and sealing them together to form an in-process assembly. Internal cavities are formed in the assembly prior to sealing. The assembly is subjected to high temperature and pressure to diffusion bond the sheets together at selected points. The cavities are then subjected to internal pressure at high temperature in order to inflate and superplastically deform the assembly to the desired shape. Excess material may be machined off after inflation.