Abstract: A system for attaching a phenolic panel to a metal part includes a phenolic laminate panel having (i) a phenolic panel, (ii) a ferromagnetic susceptor bonded at an inner side of the phenolic panel via higher melting point adhesive and (iii) a non-magnetic shield having an outer side bonded at an inner side of the ferromagnetic susceptor via higher melting point adhesive. A lower melting point adhesive is applied at an inner side of the non-magnetic shield opposite from the outer side of the non-magnetic shield. With the phenolic laminate panel disposed at a metal part, an electromagnetic field is generated at the phenolic laminate panel to heat the phenolic laminate panel to a temperature greater than the melting point of the lower melting point adhesive and less than the melting point of the higher melting point adhesive to bond the phenolic laminate panel to the metal part.

Abstract: A method for densifying a material includes arranging the material in a cavity of a mold and applying pressure to the material in the mold. While applying pressure to the material in the mold, a magnetic field is applied to the material in the mold to cause the material to transform between a first allotrope phase and a second allotrope phase. Applying the magnetic field to the material includes magnetic cycling, which includes one or more iterations of adjusting the magnetic field to a first strength, and then adjusting the magnetic field to a second strength. The method includes determining a density of the material during the magnetic cycling and, responsive to determination that the determined density reaches a threshold density, stopping the magnetic cycling.

Abstract: Assisted magnetic forming uses a magnetic field to assist in the forming or molding of metallic and non-metallic materials. For example, such a forming process may form a blank of ferromagnetic metals like high-strength steel and high-hard armor, non-ferromagnetic metals like aluminum and magnesium, as well as non-metals like ceramics, plastics, and fiber-reinforced composites into formed or molded parts. The magnetic field is generated to partially or completely saturate the blank during the forming process, which increases the blank's formability and/or moldability while in the presence of the magnetic field.

Abstract: A powdered material preform includes a pressed powdered metal or other powdered material, where the preform is processed and sealed so that a skin or shell is formed at the outer surface of the preform (such as via melting an outer layer or surface of the preform or via adding an outer layer around the preform or via a combination thereof), with an inner portion of the preform comprising pressed powdered material. The skinned preform may comprise a shape that is generally similar to that of a final product or part to be formed, or may simply comprise a puck or shape of approximately the same mass of the shape being formed, and the skinned preform is suitable for use in subsequent densification and/or consolidation processes or combinations thereof to form the final, fully processed part.

Abstract: Assisted magnetic forming uses a magnetic field to assist in the forming or molding of metallic and non-metallic materials. For example, such a forming process may form a blank of ferromagnetic metals like high-strength steel and high-hard armor, non-ferromagnetic metals like aluminum and magnesium, as well as non-metals like ceramics, plastics, and fiber-reinforced composites into formed or molded parts. The magnetic field is generated to partially or completely saturate the blank during the forming process, which increases the blank's formability and/or moldability while in the presence of the magnetic field.

Abstract: A method of forming and quenching a product via electrically heating includes providing tools that have been electrically heated, providing a die forming shell for supporting a component and for defining a final shape of a formed product formed from the component, and providing a support structure for supporting the die forming shell during the heating of the component or tools. Two portions of the die forming shell are joined together so that an inner surface of the two portions cooperate to form a cavity that defines the shape of the formed product. The component is formed into the formed product, whereby the component is (a) heated before the formed product is formed and/or (b) heated while the formed product is formed. The formed product is quenched via conductive quenching through the die forming shell by at least one of water and a gas.

Abstract: A powdered material preform includes a pressed powdered metal or other powdered material, where the preform is processed and sealed so that a skin or shell is formed at the outer surface of the preform (such as via melting an outer layer or surface of the preform or via adding an outer layer around the preform or via a combination thereof), with an inner portion of the preform comprising pressed powdered material. The skinned preform may comprise a shape that is generally similar to that of a final product or part to be formed, or may simply comprise a puck or shape of approximately the same mass of the shape being formed, and the skinned preform is suitable for use in subsequent densification and/or consolidation processes or combinations thereof to form the final, fully processed part.

Abstract: A heat assisted friction stir welding system and fastener for use therewith allows the joining a variety of dissimilar materials, including joining composites and plastics to metal, in which the fastener becomes part of the bond. The fastener can be constructed from multiple materials, allowing for the joining of dissimilar metals. Heating the materials to be joined reduces the clamping force and torque required by the friction stir weld process. The result is a bond that is stronger with less energy input.