Abstract: Methods, systems, and apparatuses are disclosed for the manufacture of composite components having incorporated reinforcing structures machined into composite material substrates, and composite components manufactured according to disclosed methods, and assemblies and larger structures comprising the composite material components.

Abstract: An exterior panel is formed of superplastic materials, including an exterior skin of titanium to accommodate high thermal stresses imposed on hypersonic transport vehicles during hypersonic flight. The exterior skin is fixed to an underlying reinforcing skeletal structure consisting of a superplastic formable reinforcement (SFR) layer, for example a titanium, zirconium, and molybdenum (TZM) alloy, which supports the exterior skin whenever the latter may be heated to temperatures exceeding 1200 degrees Fahrenheit. The exterior panel includes a separate interior skin configured for attachment to a frame member such as a rib, stringer, or spar of the hypersonic transport vehicle. A multicellular core is sandwiched between the exterior and interior skins to impart tensile and compressive strength to the exterior panel. In one disclosed method, the core is superplastic formed and diffusion bonded to the exterior and interior skins.

Abstract: The present invention discloses a method for pressure forming of an aluminum alloy special-shaped tubular component by using an ultra-low temperature medium. By means of the characteristics that the forming property of an aluminum alloy tube is greatly improved under ultra-low temperature conditions, a tube is cooled and pressurized in a die through an ultra-low temperature medium, so that the tube forms a special-shaped tubular component at an ultra-low temperature. In the method for pressure forming of an aluminum alloy special-shaped tubular component by using an ultra-low temperature medium, the ultra-low temperature medium is not only used for cooling the die and the tube, but also used for pressurization to achieve flexible loading of the tube, which is favorable for forming complex special-shaped tubular components with varied cross-sections.

Abstract: An expanded laminate and method of forming an expanded laminate are disclosed. In at least one embodiment, the method includes selectively applying a relatively high temperature-resistant material to a surface of a first metal sheet to form a covered portion and an uncovered portion and diffusion bonding the first metal sheet to a second metal sheet at the uncovered portion to form a bonded region and an unbonded region. Pressurized gas may be introduced between the first and second metal sheets to expand the first and second metal sheets in the unbonded region. The metal sheets may be aluminum sheets. The sheets may be positioned in a die having a plurality of cavities such that when the pressurized gas is introduced the sheets expand into the cavities. The diffusion bonding may be performed by applying pressure, for example, using rollers.

Abstract: A device and a method of assembly by brazing or diffusion-welding under a gaseous pressure is provided to make structures for a nacelle of an aircraft turbojet engine such as an inner fixed structure. Sealing of the assembly space inside which the parts to assemble are disposed is provided by tie members exerting a mechanical pressure on mold elements. The tie members include jaws made of a first material and a holding element made of a second material. The first material has a thermal expansion coefficient higher than that of the second material.

Abstract: A method for treating a bipolar plate for a fuel cell includes passing the bipolar plate between two rows of parallel straightening rollers. Action of the parallel straightening rollers on the bipolar plate result in opposite faces of the bipolar plate being on parallel planes.

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: A housing includes: a bottom cover; a top cover; and a reinforcing structure that is disposed in a space divided by the bottom cover and the top cover and has a flat portion, a rising wall member erected on a rim of the flat portion, and a joining portion extending from a rim of the rising wall member, or a curved portion, and a joining portion extending from a rim of the curved portion, the joining portion of the reinforcing structure being joined to the bottom cover or the top cover. The area of the joining portion is within a range of 10 cm2 or more and 100 cm2 or less, and the maximum value of the height of the reinforcing structure is within a range of 3 mm or more and 30 mm or less.

Abstract: A method (300) of using hot isostatic pressing to join metallic members that form a component in a gas turbine engine is disclosed. The method (300) may include applying (306) a surface treatment to the outer surfaces (14, 15, 16, 20, 22, 24) of first and second metallic members (12, 18) based on whether a mechanical or metallurgical joint for the component is desired. Additionally, the method (300) may include aligning (310) the outer surfaces (14, 15, 16, 20, 22, 24) of the first and second metallic members (12, 18) to create a sealed cavity, which encompasses the joint, between the first and second metallic members (12, 18). Once the outer surfaces (14, 15, 16, 20, 22, 24) are aligned, the method (300) may include subjecting (314) the members (12, 18) to hot isostatic pressing such that material from the first metallic member (12) flows into a recess (26) within the second metallic member (18) so as to join the first and second metallic members (12, 18) to form a consolidated component (10).

Abstract: A method includes disposing a hydride of a transition metal on a first metallic material, where at least one of the first metallic material or a second metallic material includes a surface oxide layer. The method includes performing a diffusion bonding operation to bond the first metallic material to the second metallic material. During the diffusion bonding operation, the hydride of the transition metal chemically reacts with the surface oxide layer.

Abstract: Aspects of the disclosure are directed to a bonding of a first skin and a second skin to a core material, coupling a sheet to the first skin to form with the first skin an enclosure containing the second skin and the core material, exposing the first skin, the second skin, and the core material to heat, and based on the exposition of heat, applying pressure via the enclosure to the first skin to cause the first skin to deform and expand to a shape of a die.

Abstract: A heat exchanger includes an inner tube extending longitudinally along a central axis and having an inner surface bounding a product chamber and an outer surface having a plurality of channels disposed at circumferentially spaced intervals in alternating relationship with a plurality of fins about the circumference of the outer surface of the inner tube; and a longitudinally extending outer tube disposed coaxially about and circumscribing the inner tube in radially spaced relationship, the outer tube having an inner surface contacting the plurality of fins of the inner cylinder, the outer surface being welded to the fins at a plurality of weld locations.

Abstract: Within examples, a method of manufacturing a double-walled titanium conduit is described. Example methods include stitch welding multiple concentric sheets to form a stitch layer, providing the stitch layer between an inner wall and an outer wall of the double-walled titanium conduit, circumferentially seam welding the inner wall and the outer wall to the stitch layer to create a welded assembly, die forming the welded assembly at temperature and pressure to form inner structures between the multiple concentric sheets according to stitch welding lines and to enable a diffusion bond process among the inner wall, the stitch layer, and the outer wall, and removing the double-walled titanium conduit from the die.

Abstract: There is proposed a method of forming an inflated aerofoil (1), the method comprising the steps of: forming a layered, planar pre-form (30); providing at least one stress-relieving opening (44, 45, 46, 47) through the pre-form; hot creep forming and inflating the pre-form (30) to form an intermediate aerofoil; and subsequently removing material from the intermediate aerofoil, including at least a region containing the or each stress-relieving opening (44, 45, 46, 47), to form a finished aerofoil.

Abstract: A game fence roll having a panel and skirt is provided along with a process for installation of a fence using the roll. A wire-mesh security fence panel and security fence is provided. In at least on example the fence panel includes: a first set of substantially parallel wires, each wire having a first and a second end; a second set of substantially parallel wires, the second set of wires being welded across the first set on one picket-wire side of the first set; a cross-wire-side connection strip welded across the first end of the first set on the picket-wire side of the first set; and an opposite side connection strip welded across the second end of the first set on the opposite side of the picket-wire side. In one such example each connection strip has an outside edge and each outside edge is equally spaced from the end of the wires to which the strip is welded.

Abstract: Within examples, a method of manufacturing a double-walled titanium conduit is described. Example methods include stitch welding multiple concentric sheets to form a stitch layer, providing the stitch layer between an inner wall and an outer wall of the double-walled titanium conduit, circumferentially seam welding the inner wall and the outer wall to the stitch layer to create a welded assembly, die forming the welded assembly at temperature and pressure to form inner structures between the multiple concentric sheets according to stitch welding lines and to enable a diffusion bond process among the inner wall, the stitch layer, and the outer wall, and removing the double-walled titanium conduit from the die.

Abstract: A non-cylindrical pressure vessel storage tank is disclosed. The storage tank includes an internal structure. The internal structure is coupled to at least one wall of the storage tank. The internal structure shapes and internally supports the storage tank. The pressure vessel storage tank has a conformability of about 0.8 to about 1.0. The internal structure can be, but is not limited to, a Schwarz-P structure, an egg-crate shaped structure, or carbon fiber ligament structure.

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 method for making a cellular seal member for a turbine is disclosed. The method includes, in sequence, forming a diffusion aluminide coating on a surface of a cellular seal to form a coated cellular seal. The method also includes brazing the coated cellular seal to a seal substrate.

Abstract: A process for manufacturing a shaped sandwich panel includes arranging a sandwich panel adjacent a die. The sandwich panel includes a core layer arranged between and connected to a first layer and a second layer. The core layer includes a plurality of apertures that extend through the core layer to the first layer. The first layer engages the die. Fluid within the apertures is pressurized to a pressure adequate to at least partially form the sandwich panel to a geometry of the die.

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 blade (20) for a turbomachine by superplastic forming and diffusion bonding a first layer (18), a second layer (16) and a membrane (2), the membrane (2) being disposed between the first and second layers (18, 16), the method comprising: applying a stop-off material in a first predetermined pattern between the first layer (18) and the membrane (2) so as to prevent a diffusion bond from forming between the first layer and the membrane across said first predetermined pattern; and applying the stop-off material in a second predetermined pattern between the second layer (16) and the membrane (2) so as to prevent a diffusion bond from forming between the second layer and the membrane across said second predetermined pattern.

Abstract: A process for producing a fleece having metallic wire filaments, includes at least the following steps: a) forming a layer including wire filaments; b) producing first cohesive connections between at least some of the metallic wire filaments in a first joining process; and c) producing second cohesive connections between metallic wire filaments in a second joining process. A process for producing a honeycomb body having at least one fleece, a fleece, a honeycomb body, an apparatus and a vehicle using fleeces in the treatment of exhaust gas from motor vehicles, are also provided.

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 honeycomb core is created from a stack of metal sheets that are welded together using a serpentine weld path. Each sheet in the stack is welded to the sheet underneath. All the odd-numbered sheets, excluding the bottom sheet, are welded using a first serpentine welding pattern that includes a plurality of long welds and a plurality of short welds. All the even-numbered sheets are welded using a second serpentine welding pattern that includes a plurality of long welds and a plurality of short welds, such that the long welds of the second serpentine welding pattern are shifted from the long welds of the first serpentine welding pattern. When a sufficient number of sheets have been welded, the stack is trimmed to remove the short welds. The stack is expanded by pulling the sheets one from another to form the honeycomb core.

Abstract: The present invention relates to UOE steel pipe excellent in collapse characteristics formed by the UOE production method and a method for forming this UOE steel pipe, said UOE steel pipe characterized in that a ratio between compression and tension of yield strength in the circumferential direction is at least 1.05 near the inside surface and is at least 0.9 to not more to 1.0 from the center of plate thickness to the outside surface.

Abstract: A preform for forming a structural assembly that defines a complex contour is provided. The preform and, hence, the structural assembly includes first and second skin members and a cellular core member between the first and second skin members. The skin members and/or the core member can be formed to a shape that corresponds to the desired contour of the structural member before the preform is assembled, e.g., by superplastic forming. That is, the first skin member can be disposed against a contour surface of a die to restrain the preform to the contour defined by the surface. A pressurized fluid is provided against the second skin member to urge the preform against the contour surface. A pressurized fluid is also injected in the first chamber to support the cellular core member. The preform is heated to a bonding temperature before or after being disposed against the contour surface so that the core and skin members are bonded to form the structural assembly.

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 twin-wall pipe comprises an internal pipe and an external pipe. The external pipe is corrugated, having elevations and troughs. The twin-wall pipe is further provided with a socket. In a transition portion towards the twin-wall pipe and the socket, provision is made for at least one overflow passage which interconnects the clearance between the external pipe and internal pipe in the vicinity of the transition portion and an adjacent elevation. a?b refers to the radial height b of the overflow passage relative to its width a in the circumferential direction.

Abstract: The present invention relates to UOE steel pipe excellent in collapse characteristics formed by the UOE production method and a method for forming this UOE steel pipe, said UOE steel pipe characterized in that a ratio between compression and tension of yield strength in the circumferential direction is at least 1.05 near the inside surface and is at least 0.9 to not more to 1.0 from the center of plate thickness to the outside surface.

Abstract: A preform with edges overlapped and jointed each other and first and second outer members for forming outer surfaces of a hydroformed product, and reinforcement members that are jointed to the first and second outer members to form reinforcement ribs that divide a hollow cross section of the outer surfaces, the reinforcement members having dimensions capable of suppressing elongation in a tensile direction due to a tensile force that develops during hydroforming.

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: A current collector plate, also called a bipolar plate, for a fuel cell includes two facing metal sheets with fluid channels for the fuel (often hydrogen) on the non-facing side of one sheet and fluid channels for air on the non-facing side of the other sheet. Such a plate is made by applying a patterned coating of particles of a soft and reactive metal to at least one of the sheets and rolling them together so that the soft metal particles deform and interact with the facing sheets to selectively join them at the patterned areas. Pressurized fluid is introduced between the sheets to expand non-bonded portions and define the fluid channels.

Abstract: A method for producing parts including at least one internal cavity. In the method at least two metal sheets are diffusion bonded; then the bonded metal sheets are bent; and then each of internal cavities is inflated by superplastic forming. The method is carried out by a mold allowing at least one first part to be diffusion bonded and then bent while inflating at least one second part by superplastic forming during a single operation, whereby the mold is heated. The method can be applied, e.g., to the field of aeronautics.

Abstract: A method for superplastically forming a preform to manufacture a structural assembly with a contoured configuration is provided. The preform includes first and second structural members in a stacked configuration, with at least one additional peripheral member abutting the stack and joined thereto by a friction welded butt joint. In some cases, the preform defines dissimilar forming characteristics throughout, such as variations in material or thickness according to the amount of superplastic forming to be performed in each portion of the preform.

Abstract: A preform with edges overlapped and jointed each other and first and second outer members for forming outer surfaces of a hydroformed product, and reinforcement members that are jointed to the first and second outer members to form reinforcement ribs that divide a hollow cross section of the outer surfaces, the reinforcement members having dimensions capable of suppressing elongation in a tensile direction due to a tensile force that develops during hydroforming.

Abstract: A method for producing aluminum-containing honeycomb bodies includes providing at least partly structured aluminum-based metal foils. The at least partly structured metal foils are stacked and/or wound to form a honeycomb structure having passages. The metal foils are heated from an open end face of the passages with at least one radiant heater. The honeycomb structure is heated in at least one subregion in such a way that the at least one subregion has a temperature between approximately 450° C. and approximately 600° C. after approximately 2 seconds to approximately 30 seconds. The metal foils are connected together in the at least one subregion by technical joining.

Abstract: A method for making a current collector plate includes providing a first sheet of material having a first bonding face and a first outer face. A second sheet of material is provided having a second bonding face and a second outer face. A work area is defined on at least one of the first bonding face and the second bonding face. The first and second sheets are bonded together at a bonding area which is different from the work area. The bonded first and second sheet is placed into a die having a pattern defining at least one flow channel. Fluid is injected between the first and second sheets thereby causing at least one of the first and second sheets to project outward at the work area causing at least one flow channel to be formed in the work area as defined by the die pattern.

Abstract: Two metal blocks (50, 52) are welded to respective metal sheets (30, 32) to form sealed assemblies. The sealed assemblies are then diffusion bonded together to form two metal preforms (54, 56). The thick ends (36) and (40) of the metal sheets (30, 32) and the metal blocks (50, 52) are hot formed so that a continuation of the plane X of the first surfaces (42, 46) of the metal sheets (30, 32) extends through and across the metal blocks (50, 52). The metal preforms (54, 56) are machined to remove the portion of the metal blocks (50, 52) extending above the first surfaces (42, 46) of the metal sheets (30, 32) respectively. The metal preforms (54, 56) and a metal sheet (58) are assembled into a stack (64). The metal preforms (54, 56) and the metal sheet (58) are diffusion bonded together and then superplastically formed to produce a hollow fan blade (10). The method enables thinner metal workpieces with better microstructure to be used and increases the yield of metal workpieces.

Abstract: A method and device to elongate a solder joint are provided. The method begins by forming an elongator on a first substrate. The elongator comprises an expander and an encapsulant to encapsulate the expander. A solder joint is formed to connect the first substrate to a second substrate. Thereafter, the encapsulant is softened to release the expander from a compressed state to elongate the solder joint. The device to elongate a solder joint comprises a substrate having an elongator formed on it. The elongator includes an expander in a compressed state and an encapsulant to encapsulate the expander.

Abstract: A process of forming a structure by diffusion bonding and superplastic forming includes forming a pack from at least one skin sheet and at least one core sheet, placing the pack in a mould and heating it. A gas is injected between the skin sheet and the core sheet to urge the skin sheet against an internal face of the mould, thereby forming a cavity. Gas is also injected on the other side of the core sheet to urge it against the skin sheet, and gas pressure is maintained on said side of the core sheet thereby forming a diffusion bond between the skin sheet and the core sheet. Helium gas is used to maintain a regulated pressure of helium in the cavity between the skin sheet and the core sheet, which allows such gas trapped between the skin sheet and the core sheet to diffuse through the core sheet.

Abstract: A liquid phase diffusion bonding method for dissimilar metal sheets by allowing a galvanized steel sheet and an aluminum alloy sheet to come into close contact with each other and pressing both sheets by using a first mold of a liquid phase diffusion bonding apparatus and a second mold of the same; and heating the sheets at approximately the same heat-up rate and at approximately the same temperature to perform liquid phase diffusion bonding of the sheets by using induction heat generated by applying high frequency currents to a first high frequency induction heating coil provided on the first mold and a second high frequency induction heating coil provided on the second mold. The first high frequency induction heating coil and the second high frequency induction heating coil are positioned to sandwich the sheets at predetermined distances from the sheets, respectively.

Abstract: A method for forming an article having a wall that is at least partially fabricated from tubing. The methodology employs a pressurized fluid to deform the tubing such that an outer surface of the tubing substantially conforms to a predetermined first wall configuration, an inner surface of the tubing substantially conforms to a predetermined second wall configuration and each of segment or loop of the tubing is substantially contiguous with at least one other segment or loop between the first and second surfaces.

Abstract: A multisheet structure is made using compression diffusion bonding according to the present invention using a CRES template to apply increased pressure in the areas designated for diffusion bonds (DB) to improve the bond quality and to reduce the processing time. The CRES template is patterned to correspond with the DB arrangement in the superplastically formed part. The forming press forces the template against the pack of SPF sheets to provide 300-1200 psi or more pressure along the bond lines to speed their formation.

Abstract: We combine superplastic forming (SPF) with adhesive bonding (AB) to produce quality multisheet sandwich panel structures, especially those using a superplastic aluminum alloy, such as Al 2004, Al 8090, or Al 1570. We produce the parts with improved energy efficiency and at lower cost. We heat the multisheet pack having an adhesive, preferably a polyimide, between the core sheets and the face sheets to its superplastic forming range. Then, we superplastically form the pack to define adhesive bonds between the sheets in the core and between the core and the face sheets with the flowing adhesive. Finally, we cool the formed pack below the superplastic range to set the adhesive.

Abstract: A structure (10) in the shape of an aerodynamic panel in which adjacent cells (20a, 20b) are formed by placing a stack of three metal plates in a mold. After diffusion welding of the plates at the required locations, a first variable pressure is applied in a first series of cells (20a) formed between the outer plate and the intermediate plate and a second independent pressure approximately constant and lower than the first is applied in the other cells (20b) and on the inner face of the stack. Thus, this partially forms the cells and shapes the structure in contact with a complementary surface of the mold. The final conformation of the cells and the structure is obtained by applying a second pressure cycle in the cells and on the inner face of the stack.

Abstract: In a method for joining a steel tube with an aluminum rib, a zinc-aluminum alloy layer, having an aluminum content of 0.5% by wt. to 20% by wt., is applied to the surface of the steel tube or the aluminum rib, and then a fluxing agent in the form of cesium-aluminum tetrafluoride is applied between the steel tube and the aluminum rib at room temperature before or during the mechanical contact of the aluminum rib with the steel tube. The steel tube provided with the aluminum rib is then heated to a soldering temperature of between 370° C. and 470° C. and subjected to room temperature to cool down.

Abstract: A method of forming sheets of superplastically formable material into a three dimensional article, the sheets being joined together along diffusion bonds to form discrete cells, at least one gas path being provided through the bond between cells. The sheets are heated to a temperature at which they exhibit superplastic properties and a gas injected between the sheets to expand the cells, the gas paths allowing the injected gas to pass from cell to cell. The edges of the gas paths are locally heated to change the microstructure of the sheets in the edge areas, which reduces the flow resistance of the edges under superplastic forming conditions and thereby reduces the propensity of the diffusion bonds bordering the gas transfer holes to peel apart under the forces of the inert gas exerted on the sheets at the gas transfer paths.

Abstract: A value housing having overlapped inner and outer members is fabricated by a process including placing the members in position where one side of the joint is accessible for welding and the opposite side is inaccessible, single welding from the accessible side and brazing the opposite side. The brazing step provides for filling of minute gaps in the joint at the inaccessible side. A bronze welding type brazing alloy and heating at a temperature of 1800 to 1900 degrees Fahrenheit are employed.

Abstract: An efficient and effective process for manufacturing of hardened aluminum components is achieved by coordinating the material preparation steps with the forming steps. The resulting product is a hardened aluminum component with desirable strength characteristics. The process includes initial heating of sheet material in order to prepare it for further processing. The sheet material is then quenched to promote appropriate material conditioning. A product forming sub-process is then undertaken in a relatively short period of time following the quenching. The product forming is done while the material is in a relatively ductile condition, thus easing forming operations, and avoiding product spring-back problems. Lastly, the component is naturally aged, to provide the final hardening operations. The resulting product has very desirable strength characteristics, due to the combined forming and hardening process.