Abstract: A propulsion system comprises a turbine engine, and an engine nacelle including an SPF/DB inner wall having a hot side face sheet against the engine and a cold side face sheet that has noise attenuation openings.

Abstract: A hybrid structure comprises a metallic built-up sandwich structure, and a monolithic superplastic formed and diffusion bonded structure joined to the built-up sandwich structure.

Abstract: A ceramic refractory insulation block for a hot press is provided that is reinforced in a manner that reduces the likelihood of cracking and, once cracked, reduces the rate at which the crack will propagate through the ceramic refractory insulation block. The ceramic refractory insulation block includes a ceramic body defining a plurality of outer surfaces. Each of the surfaces is a planar surface. The ceramic body also defines a centerline about which the ceramic body is subjected to a bending moment. The ceramic refractory insulation body also includes a plurality of reinforcing rods extending through the ceramic body. The reinforcing rods have a greater flexural strength than the ceramic body. One or more of the plurality of reinforcing rods extend through the ceramic body on each of the opposed sides of the centerline about which the ceramic body is subjected to the bending moment.

Abstract: A hybrid structure comprises a metallic built-up sandwich structure, and a monolithic superplastic formed and diffusion bonded structure joined to the built-up sandwich structure.

Abstract: One aspect of the disclosure relates to a die comprising a primary plate and secondary plates. The secondary plates comprise through weld holes formed along a direction. The through weld holes of adjacent secondary plates do not overlap when viewed in the direction along which the though weld holes are formed. The primary plate is coupled to at least one secondary plate abutting the primary plate by first welds located in the through weld holes. The secondary plates abutting each other are coupled by second welds located in the through weld holes.

Abstract: A method of forming a pack in a die by superplastic formation and diffusion bonding comprises applying a forming pressure within the pack to expand the pack within the die; and supplying gas between the die and the pack to apply a back pressure around an outside of the pack while the pack is being expanded to counteract the forming pressure to reduce surface mark off.

Abstract: A propulsion system comprises a turbine engine, and an engine nacelle including an SPF/DB inner wall having a hot side face sheet against the engine and a cold side face sheet that has noise attenuation openings.

Abstract: A method of forming a pack in a die by superplastic formation and diffusion bonding comprises applying a forming pressure within the pack to expand the pack within the die; and supplying gas between the die and the pack to apply a back pressure around an outside of the pack while the pack is being expanded to counteract the forming pressure to reduce surface mark off.

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 method of superplastic forming of titanium packs and an associated assembly is provided. The titanium packs can include sheets having different granular structures so that the different sheets are adapted to superplastically form at different temperatures. One or more of the sheets can be formed at a temperature that is below the superplastic forming temperature of another sheet in the pack. In some cases, the occurrence of markoff can be reduced or eliminated.

Abstract: A method for providing a stop-off material on a workpiece is provided, as is an associated assembly. A maskant is provided on the workpiece such that a first portion of the workpiece is exposed and a second portion of the workpiece is covered by the maskant. The stop-off is then disposed, with the maskant on the workpiece preventing the stop-off from being applied to the second portion of the workpiece. The maskant is removed from the workpiece leaving the stop-off disposed on a select portion of the workpiece. The removal of the maskant can leave the workpiece substantially free of debris. Thereafter, the workpiece can be further processed, e.g., by diffusion bonding, with the stop-off preventing diffusion bonding of part of the workpiece.

Abstract: A method for superplastically forming and/or diffusion bonding a structural member and an associated structural member are provided. The structural member is formed at least partially of titanium, e.g., Ti-6A1-4V, and has a fine grain structure. For example, the grain size of the material of the structural member can be less than 2 micron. The member can be superplastically formed and/or diffusion bonded at a reduced temperature, thereby potentially reducing the thermal energy required for forming and bonding, and also reducing the effects of heating on the structural member and the forming apparatus. In addition, the structural member can be formed at an increased strain rate.

Abstract: Apparatus and methods for single sheet forming using induction heating include a pair of dies defining a die cavity for containing a workpiece, which is inductively heated by an oscillating magnetic field within the die cavity. A susceptor is positioned between the workpiece and one die surface defined by one of the dies. The susceptor is capable of coupling with the oscillating magnetic field to induce a current within the susceptor to heat the susceptor. The susceptor transfers heat to the workpiece. An inlet for pressurized forming fluid injects the fluid between the susceptor and the workpiece to form the workpiece into direct contact with a forming surface defined by one of the dies. The susceptor may be electrically connected to the workpiece to inhibit electrical arcing from the susceptor to adjacent electrically conductive components when current is induced in the susceptor.

Abstract: A susceptor connection system and an associated apparatus and method are provided. The susceptor connection system includes at least one shoe that can be urged against a peripheral edge portion of the susceptors by a compression device. In this regard, each shoe can urge the edge portions of the susceptors together to achieve electrical contact therebetween, e.g., so that an induced current can flow between the susceptors to heat the susceptors and a workpiece. In addition, each shoe can define a passage for circulating a coolant to cool the edge portions and thereby reduce the oxidation and contact resistance between the susceptors.

Abstract: Apparatus and methods for single sheet forming using induction heating include a pair of dies defining a die cavity for containing a workpiece, which is inductively heated by an oscillating magnetic field within the die cavity. A susceptor is positioned between the workpiece and one die surface defined by one of the dies. The susceptor is capable of coupling with the oscillating magnetic field to induce a current within the susceptor to heat the susceptor. The susceptor transfers heat to the workpiece. An inlet for pressurized forming fluid injects the fluid between the susceptor and the workpiece to form the workpiece into direct contact with a forming surface defined by one of the dies. The susceptor may be electrically connected to the workpiece to inhibit electrical arcing from the susceptor to adjacent electrically conductive components when current is induced in the susceptor.