Abstract: An outward-opening, plug-type cargo door for an aircraft is movable between a closed position and an open position in which the door is spaced from the cargo bay opening in a canopy orientation above and outboard of the cargo bay opening. The door hinges are directly driven by irreversible rotary actuators such that the weight of the door cannot back-drive the actuators. The door must be powered to the opened and closed positions thereby eliminating the necessity of a strut to prop the door open when cargo is being loaded and unloaded. The rotary actuators are mounted to the aircraft structure independently of the hinge mechanism's attachment to the aircraft structure so that the actuators can be removed and replaced if necessary without disturbing the hinge mechanism or door linkage. The hinge linkage has been simplified to provide fewer parts for the linkage. The door is manually unlatched from either the interior or exterior of the aircraft through a dual handle system.

Abstract: A method of making an integral structural member including first and second generally planar sections joined together at a transition section which defines fillets at opposite sides thereof. A first workpiece is positioned in a die with a slug of fillet material located adjacent thereto, a second workpiece is superplastically formed against a portion of the first workpiece and against a forming surface of the die, and a portion of the second workpiece combines with the slug of fillet material against the forming surface and the first workpiece to provide the fillets along both sides of the transition section for strengthening the transition section. Temperatures and pressures required for accomplishing the superplastic forming are maintained at diffusion bonding levels for a period of time sufficient to provide diffusion bonding between the workpieces and diffusion bonding of the workpieces to the fillet material.