Abstract: Disclosed herein are induction heating cells and methods of using these cells for processing. An induction heating cell may be used for processing (e.g., consolidating and/or curing a composite layup having a non-planar portion. The induction heating cell comprises a caul, configured to position over and conform to this non-planar portion. Furthermore, the cell comprises a mandrel, configured to position over the caul and force the caul again the surface of the feature. The CTE of the caul may be closer to the CTE of the composite layup than to the CTE of the mandrel. As such, the caul isolates the composite layup from the dimensional changes of the mandrel, driven by temperature fluctuations. At the same time, the caul may conform to the surface of the mandrel, which can be used to define the shape and transfer pressure to the non-planar portion.

Abstract: A smart susceptor assembly including an electromagnetic flux source such as one or more inductors, a geometrically complex-shaped susceptor having one or more contours, and a cladding on or over the susceptor. The cladding can alter both the thermal performance and the electrical operation of the smart susceptor assembly. With regard to thermal performance, the cladding can function as a passive heat exchanger to dissipate thermal energy across the surface of the susceptor. With regard to electrical operation, the cladding can provide a current path after portions of the susceptor heat and become low or non-magnetic.

Abstract: A panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.

Abstract: Disclosed are induction heating cells comprising tensioning members with non-magnetic metal cores. Also disclosed are methods of operating such cells, for example, to process composite parts. The non-magnetic metal cores of the tensioning members provide excellent tensile strength. Furthermore, the non-magnetic metal cores allow forming long tensioning members leading to large induction heating cells for processing large composite parts, such aircraft fuselage parts, wing parts, and the like. The diameter of these non-magnetic metal cores is less than the induction heating threshold for magnetic fields used during operation of the cells, which ensures limited or no interaction of the cores with the magnetic fields. The cores can be arranged into a tensioning member extending through and compressing the die of an induction heating cell. When multiple cores are used, these cores are electrically insulated from each other, e.g., using an insulating shell or spacing these cores away from each other.

Abstract: Disclosed herein are induction heating cells and methods of using these cells for processing. An induction heating cell may be used for processing (e.g., consolidating and/or curing a composite layup having a non-planar portion. The induction heating cell comprises a caul, configured to position over and conform to this non-planar portion. Furthermore, the cell comprises a mandrel, configured to position over the caul and force the caul again the surface of the feature. The CTE of the caul may be closer to the CTE of the composite layup than to the CTE of the mandrel. As such, the caul isolates the composite layup from the dimensional changes of the mandrel, driven by temperature fluctuations. At the same time, the caul may conform to the surface of the mandrel, which can be used to define the shape and transfer pressure to the non-planar portion.

Abstract: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.

Abstract: Disclosed herein are induction heating cells and methods of using these cells for processing. An induction heating cell may be used for processing (e.g., consolidating and/or curing a composite layup having a non-planar portion. The induction heating cell comprises a caul, configured to position over and conform to this non-planar portion. Furthermore, the cell comprises a mandrel, configured to position over the caul and force the caul again the surface of the feature. The CTE of the caul may be closer to the CTE of the composite layup than to the CTE of the mandrel. As such, the caul isolates the composite layup from the dimensional changes of the mandrel, driven by temperature fluctuations. At the same time, the caul may conform to the surface of the mandrel, which can be used to define the shape and transfer pressure to the non-planar portion.

Abstract: Disclosed herein are induction heating cells and methods of using these cells for processing. An induction heating cell may be used for processing (e.g., consolidating and/or curing a composite layup having a non-planar portion. The induction heating cell comprises a caul, configured to position over and conform to this non-planar portion. Furthermore, the cell comprises a mandrel, configured to position over the caul and force the caul again the surface of the feature. The CTE of the caul may be closer to the CTE of the composite layup than to the CTE of the mandrel. As such, the caul isolates the composite layup from the dimensional changes of the mandrel, driven by temperature fluctuations. At the same time, the caul may conform to the surface of the mandrel, which can be used to define the shape and transfer pressure to the non-planar portion.

Abstract: A panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.

Abstract: Methods, apparatuses and systems are disclosed for chemically etching parts by generating an enclosed chemical etching chamber in contact with a part surface and directing a flow of chemical etchant solution in contact with a part region to be etched.

Abstract: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.

Abstract: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.

Abstract: A smart susceptor assembly including an electromagnetic flux source such as one or more inductors, a geometrically complex-shaped susceptor having one or more contours, and a cladding on or over the susceptor. The cladding can alter both the thermal performance and the electrical operation of the smart susceptor assembly. With regard to thermal performance, the cladding can function as a passive heat exchanger to dissipate thermal energy across the surface of the susceptor. With regard to electrical operation, the cladding can provide a current path after portions of the susceptor heat and become low or non-magnetic.

Abstract: Disclosed herein are induction heating cells and methods of using these cells for processing. An induction heating cell may be used for processing (e.g., consolidating and/or curing a composite layup having a non-planar portion. The induction heating cell comprises a caul, configured to position over and conform to this non-planar portion. Furthermore, the cell comprises a mandrel, configured to position over the caul and force the caul again the surface of the feature. The CTE of the caul may be closer to the CTE of the composite layup than to the CTE of the mandrel. As such, the caul isolates the composite layup from the dimensional changes of the mandrel, driven by temperature fluctuations. At the same time, the caul may conform to the surface of the mandrel, which can be used to define the shape and transfer pressure to the non-planar portion.

Abstract: Disclosed herein are induction heating cells and methods of using these cells for processing. An induction heating cell may be used for processing (e.g., consolidating and/or curing a composite layup having a non-planar portion. The induction heating cell comprises a caul, configured to position over and conform to this non-planar portion. Furthermore, the cell comprises a mandrel, configured to position over the caul and force the caul again the surface of the feature. The CTE of the caul may be closer to the CTE of the composite layup than to the CTE of the mandrel. As such, the caul isolates the composite layup from the dimensional changes of the mandrel, driven by temperature fluctuations. At the same time, the caul may conform to the surface of the mandrel, which can be used to define the shape and transfer pressure to the non-planar portion.

Abstract: Disclosed are induction heating cells comprising tensioning members with non-magnetic metal cores. Also disclosed are methods of operating such cells, for example, to process composite parts. The non-magnetic metal cores of the tensioning members provide excellent tensile strength. Furthermore, the non-magnetic metal cores allow forming long tensioning members leading to large induction heating cells for processing large composite parts, such aircraft fuselage parts, wing parts, and the like. The diameter of these non-magnetic metal cores is less than the induction heating threshold for magnetic fields used during operation of the cells, which ensures limited or no interaction of the cores with the magnetic fields. The cores can be arranged into a tensioning member extending through and compressing the die of an induction heating cell. When multiple cores are used, these cores are electrically insulated from each other, e.g., using an insulating shell or spacing these cores away from each other.

Abstract: A method for forming a multilayer structure from a precursor panel having an edge, the method including steps of connecting an attachment member to the precursor panel such that an edge of the attachment member is in alignment with the edge of the precursor panel and applying heat and gas pressure to expand the precursor panel.

Abstract: One aspect of the disclosure relates to a method of making a part from at least one elemental metal powder. The part has a near-net shape, a part volume, and a part density. The method includes providing a sintered preform having a sintered density and separating a portion from the sintered preform. The portion has a portion volume exceeding the part volume and a portion shape different from the near-net shape of the part. The method also includes thermally cycling the portion for a thermal-cycling time period at a thermal-cycling pressure while superplastically deforming the portion to form the part having the near net shape and the part density.

Abstract: An apparatus for forming a panel, including a first face sheet, a second face sheet and a core sheet between the first face sheet and the second face sheet, may include a molding tool defining a forming cavity shaped to correspond to the panel, a heating system positioned adjacent to the forming cavity and configured to heat the forming cavity, and a pressurization system configured to pressurize a cavity volume between the tool and the panel and pressurize a panel volume between the first face sheet and the second face sheet.

Abstract: A panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.