Abstract: A process is disclosed of explosive bonding two or more components together by forming the components into a stack, placing the stack into an envelope made of a deformable material, sealing the envelope except for an evacuation port, evacuating the interior of the envelope through the said port and subjecting the stack to explosive bonding within the envelope, thereby joining the components together; by conducting the explosive bonding in an evacuated envelope, not only are the components protected from damage during the explosion but the bonding is enhanced due to the reduced pressure of air between the components. After bonding, the stack can be subjected to superplastic forming.

Abstract: A process is described of forming a diffusion bonded article from components made of aluminum or an alloy thereof that forms a protective coating of an oxide that inhibits such bonding. The process comprises removing the oxide layer and immediately forming the components into a stack, placing the stack in the chamber of an electron beam welding device, evacuating the chamber and electron beam welding the edge regions of the stack; the welded stack can then be diffusion bonded at leisure without the oxide re-forming. The diffusion bonded article can be superplastically formed to a finished or semi-finished shape.

Abstract: In a superplastic forming/diffusion bonding process, in particular for aluminum-lithium alloys, the stop-off material in the diffusion bonding step is a porous lamellar material such as glass cloth or vermiculite paper. In one embodiment, prior to diffusion bonding, the stack of alloy sheets and lamellar material may be sealed under vacuum.

Abstract: A method is described of diffusion bonding and superplastic forming components made of aluminium or an aluminium alloy to form a composite formed article. The method involves applying stopping-off material to selected areas of the components to prevent diffusion bonding in those areas, the stopping-off material being applied by plasma spraying.

Abstract: The present invention provides a process in which components made of aluminum or an alloy thereof can be diffusion bonded together; the process involves chemically treating the components to remove aluminum oxide on the surface of the components, subjecting them to grit blasting and to a second chemical oxide removal step and finally pressing the components together under heat until they form diffusion bonds. The resulting composite can be superplastically formed to shape.