Abstract: A method of forming a hollow component with an internal structure from first and second panels includes the step of forming at least one protrusion on a surface of at least one of the first and second panels by a material deposition process. The first and second panels are assembled into a preform the panels being oriented such that each panel defines an interior and an exterior facing surface, with the at least one protrusion extending from an exterior facing surface of a panel. The preform is expanded against a die, such that the at least one protrusion is transferred from the exterior surface of a panel to the interior surface of a panel so as to define an internal structure. Forming the at least one protrusion may include encapsulating an elongate member on the surface of a panel by a material deposition process.

Abstract: A method of forming an internal structure in a hollow component that includes the steps of forming an assembly having first, second, and third plates the first and second plates each with a substantially planar surface and a surface that includes at least one protrusion and is on the exterior facing surfaces of the assembly. The third plate is sandwiched between the first and second plates. The method also includes the steps of selectively bonding portions of the third plate to sections of the first and second plates substantially opposite the at least one protrusions of the first and second plates; and forming the assembly against a die such that the at least one protrusions of the first and second plates are transferred from the exterior facing surfaces to the interior facing surfaces of the first and second plates.

Abstract: Within hollow structures, such as blade structures in a gas turbine engine, traditionally rigid girdered reinforcement has been utilised to define structure and shape. Such rigid definition can inhibit utilisation of damping fillers within the hollow structure. By providing a web former comprising spaced bond areas suspended upon angled interconnecting membranes a hollow structure is achieved which is flexible and can be used in conjunction with a damping filler to achieve desired performance. The web former supports skins defining the shape and takes some load such that the damping filler does not separate within the hollow structure.

Abstract: A method of forming a hollow component with an internal structure from first and second panels includes the step of forming at least one protrusion on a surface of at least one of the first and second panels by a material deposition process. The first and second panels are assembled into a preform the panels being oriented such that each panel defines an interior and an exterior facing surface, with the at least one protrusion extending from an exterior facing surface of a panel. The preform is expanded against a die, such that the at least one protrusion is transferred from the exterior surface of a panel to the interior surface of a panel so as to define an internal structure. Forming the at least one protrusion may include encapsulating an elongate member on the surface of a panel by a material deposition process.

Abstract: A method of forming an internal structure in a hollow component that includes the steps of forming an assembly having first, second, and third plates the first and second plates each with a substantially planar surface and a surface that includes at least one protrusion and is on the exterior facing surfaces of the assembly. The third plate is sandwiched between the first and second plates. The method also includes the steps of selectively bonding portions of the third plate to sections of the first and second plates substantially opposite the at least one protrusions of the first and second plates; and forming the assembly against a die such that the at least one protrusions of the first and second plates are transferred from the exterior facing surfaces to the interior facing surfaces of the first and second plates.

Abstract: A method of manufacturing a component by superplastic forming and diffusion bonding a first layer, a second layer, a first membrane, and a second membrane, the first and second membranes being disposed between the first and second layers with the first membrane adjacent the first layer and the second membrane adjacent the second layer, by a method of applying a stop-off material in a first predetermined pattern between the first layer and the first membrane so preventing a diffusion bond from forming between the first layer and the first membrane across regions defined by said first predetermined pattern; applying the stop-off material in a second predetermined pattern between the second layer and the second membrane preventing a diffusion bond from forming between the second layer and the second membrane across regions defined by said second predetermined pattern; and providing a damping material between the first and second membranes.

Abstract: Within hollow structures, such as blade structures in a gas turbine engine, traditionally rigid girdered reinforcement has been utilised to define structure and shape. Such rigid definition can inhibit utilisation of damping fillers within the hollow structure. By providing a web former comprising spaced bond areas suspended upon angled interconnecting membranes a hollow structure is achieved which is flexible and can be used in conjunction with a damping filler to achieve desired performance. The web former supports skins defining the shape and takes some load such that the damping filler does not separate within the hollow structure.