Abstract: Methods of transferring a metallic film to a flexible substrate using a roll-to-roll nanoforming assembly include transferring the metallic film to a nanomold such that a metal layer of the metallic film contacts the nanomold and an ablative layer of the metallic film contacts a confinement layer during continuous motion of the metallic film relative to the confinement layer. Further, the method includes directing a laser beam through the confinement layer onto the ablative layer of the metallic film to form a nanoformed metal from the metallic film as the metallic film moves relative to the confinement layer and the laser generator, and transferring the nanoformed metal onto the flexible substrate.

Abstract: A safety method for a reactor including a primary circuit and a secondary circuit fluidly isolated from the primary circuit, and a steam generator, and in the event of a meltdown of the core of the reactor with the formation of a corium bath in a bottom of the vessel and the formation of a liquid metallic layer at the surface of the corium bath, the method includes: a break-up by explosion of the fluidic insulation to set the secondary circuit in fluidic communication with the primary circuit so that the secondary fluid follows the primary circuit to flow inside the vessel over the liquid metallic layer of the corium bath.

Abstract: A method for producing a probe of a thermal flowmeter for measuring mass flow of a medium in a measuring tube, wherein a probe core is provided arranged loosely in a probe sleeve having a longitudinal axis, wherein the probe sleeve is deformed relative to the longitudinal axis completely radially in the direction of the probe core by means of high energy rate forming, wherein a material-locking connection between probe sleeve and probe core results and a rod is formed, wherein the rod represents a base body that is used for probe production, wherein a deformation speed reaches values greater than 100 m/s, and wherein the high energy rate forming includes explosive forming or magnetic forming.

Abstract: A shaped charge having a liner with three frustoconical segments and a bottom portion configured to provide consistent perforating holes over a range of distances from the shaped charge.

Abstract: A kinetic ram for a blowout preventer includes a pressure chamber having a piston movably disposed therein. A gas generating charge disposed at one end of the pressure chamber. A ram is coupled to the piston on a side of the piston opposed to the gas generating charge. The ram is arranged to move across a through bore in a blowout preventer housing disposed at an opposed end of the pressure chamber. An initial volume in the pressure chamber between the one end and the piston is chosen to limit a maximum pressure caused by actuating the gas generating charge to a predetermined maximum pressure, and/or the pressure chamber comprises a pressure relief device arranged to vent pressure in the pressure chamber above the maximum pressure.

Abstract: The present invention provides a method of explosively forming a helical tube from at least one thin-walled cylinder using a tooling assembly. The method includes inserting the at least one thin-walled cylinder into a die of the tooling assembly. The die surrounds the at least one thin-walled cylinder and includes an interior surface that defines a helical thread pattern. The method further includes surrounding the at least one thin-walled cylinder and the die with a casing of the tooling assembly. A cavity is defined by the casing and the thin-walled cylinder. The method further includes positioning an explosive charge within the cavity. The method additionally includes at least partially submerging the tooling assembly. The method further includes detonating the explosive charge. As a result, the at least one thin-walled cylinder is formed into a helical tube that corresponds with helical thread pattern of the interior surface of the die.

Abstract: A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, is provided. The process utilizes a self-healing erosive wear resistant coating on a liner of refractory metal to serve as the working surfaces of a shot chamber. Such a shot chamber is expected to have an improved service life for die casting of corrosive metals and alloys, including hot chamber die casting of aluminum alloys. An improved hot dipping process using stirring in the molten metal bath is also disclosed.

Abstract: A system for forming a particle layer on a substrate may include at least one sprayer and at least two masks configured to selectively mask a substrate in a first region and second region of the substrate. The at least one sprayer may be configured to spray particles at the substrate, where the at least two masks maintain the first region and second region substantially free of the deposited material. A heater may be employed to heat the substrate as the particles are sprayed by the at least one sprayer onto the substrate.

Abstract: An irregular-shaped cable and a method for manufacturing the cable. The irregular-shaped cable includes a conductive core formed by at least two conductive core segments having different cross-sectional shapes which are connected end to end. An insulation layer is wrapped over the conductive core segment from the outside, and the profile of the insulation layer fits with the conductive core segments. The cable can be fitted with the vehicle body. The manufacturing method includes a manufacture of the conductive core segments, a connection of the conductive core segments, and a manufacture of the insulation layer.

Abstract: An electro-hydraulic forming machine (1) for the plastic deformation of a projectile part (P13) of the wall (P1) of a workpiece (P) to be formed, preferably a cylindrical tubular workpiece, via a forming fluid (F), includes a tool (4) for applying the forming fluid on the inner face (P11) of the projectile part (P13), the application tool (4) including:—a chamber (44) intended to contain the forming fluid (F), cooperating with elements (3) for generating a shock wave in the forming fluid (F) intended to be contained in the chamber (44), and—at least one downstream port (42), intended to open opposite the projectile part (P13) of the wall (P1) to be deformed and in fluid communication with the chamber (44), in order to allow the passage of the forming fluid and for propagating the generated shock wave towards the footprint (22) of a target support (2).

Abstract: A method for increasing the fatigue strength of a tubular semifinished product for a medical implant, a tubular semifinished product for a medical implant having improved fatigue strength, and a medical implant produced from such a semifinished product.

Abstract: Systems and methods of forming articles using electromagnetic radiation are disclosed. In some aspects, the system includes a plurality of forming modules movably mounted relative to an infeed mechanism. The infeed mechanism is configured to supply pre-form articles to the plurality of forming modules, and each of the plurality of forming modules includes a multi-segment mold disposed about an electromagnetic coil. The electromagnetic coil is configured to impart an electromagnetic force on the pre-form articles when supplied with electrical energy that urges the pre-form articles into contact with the multi-segment mold to produce the formed containers.

Abstract: A system for electro-hydraulically forming a sheet metal part in an electro-hydraulic forming (EHF) machine. The part in a first shape is placed in the EHF machine between a one-sided forming die and a chamber that is filled with a liquid. An electrode is discharged in the chamber to form the part toward the forming die. The electrode is advanced within the chamber toward the part and a subsequent discharge is provided in the chamber to form the part. A gap discharge EHF machine and a wire discharge EHF machine may be used in the system.

Abstract: An electrohydraulic forming device comprising a framework, a tank, a movable enclosure comprising a cover, a mold connected to the cover by a support structure, a forming chamber and a discharge chamber with at least one electrode device. The enclosure is movable between a first position in which the tank is closed by the cover and a second position in which the discharge chamber and the forming chamber are outside the tank.

Abstract: A process monitoring method for a joining operation of a joining element at a speed of at least 5 m/s, in particular placing a bolt at least 10 m/s into at least one component with the aid of a placing device which has the following features: A plunger for placing the joining element, a buffer which limits a maximum deflection of the plunger in the joining direction, and a distance measurement with which the deflection of the plunger can be detected, wherein the process monitoring comprises the following steps: Detecting the travel of the plunger during the joining operation as a function of time in the form of a distance-time curve, detecting a placement of the plunger on the buffer, evaluating the distance-time curve such that, in the presence of at least one maximum followed by at least one minimum in the distance-time curve and without the plunger contacting the buffer, a joint connection is judged to be OK.

Abstract: The invention is intended to improve a method for explosive forming of a workpiece by means of gas explosion, in which the workpiece is arranged in a intake area of a moulding tool, wherein the intake area is at least partially filled with liquid and the explosion is triggered by ignition of an explosive gas mixture, to the effect that the method is suitable and simplified for mass production. This object is solved by a method for explosive forming of a workpiece by means of gas explosion, in which the workpiece is arranged in a intake area of a moulding tool, wherein the intake area is at least partially filled with liquid and the explosion is triggered by means of ignition of an explosive gas mixture, in which the explosive gas mixture is provided at least partially above the surface of the liquid before the ignition.

Abstract: A hydromechanical forming tool is disclosed that may include electro-hydraulic forming chambers in which a stored charge circuit may be discharged through electrodes to improve the level of detail that may be formed in a blank. The hydromechanical forming tool may include a liquid chamber at the entrance to the draw chamber to reduce friction, as the blank is drawn into the draw chamber. The draw chamber may have a movable bottom wall that is moved in tandem with the punch to reduce the amount of liquid in the draw chamber and reduce the need to pump liquid into and out of the draw chamber during a hydromechanical forming tool cycle.

Abstract: A method of reinforcing a part formed from a sheet metal panel that has a predetermined area that requires reinforcement by forming a grid pattern of V-shaped channels in the predetermined area. The grid pattern may be formed by wire electrodes in an electro-hydraulic forming tool having a one-sided die. Alternatively, the grid pattern may be formed by a plurality of electrodes that are arranged in an array that is aligned in at least two directions on the opposite side of the part from the one-sided die.

Abstract: Apparatus and methods are disclosed whereby a propellant driven water stream is used in the formation of materials made from high tensile strength alloys. High pressure developed in liquid flowing through a tubular work piece is employed to achieve desired forms. The high pressure results from superposition of compression waves generated in the course of the impact of the liquid by products of propellant combustion.

Abstract: A method for stiffening a skin field of an aircraft fuselage includes providing a skin field for an aircraft fuselage, manufacturing an integral lattice-shaped stiffening structure including a plurality of longitudinal stiffeners and connecting the stiffening structure to the skin field. The manufacturing can include the use of a tool mold having a plurality of longitudinal recesses configured to form longitudinal stiffeners and a plurality of sunken areas disposed between the longitudinal recess. The sunken areas are configured for forming respective mounts that are configured for connection to circumferential stiffeners.

Abstract: A system for electro-hydraulically forming a sheet metal part in an electro-hydraulic forming (EHF) machine. The part in a first shape is placed in the EHF machine between a one-sided forming die and a chamber that is filled with a liquid. An electrode is discharged in the chamber to form the part toward the forming die. The electrode is advanced within the chamber toward the part and a subsequent discharge is provided in the chamber to form the part. A gap discharge EHF machine and a wire discharge EHF machine may be used in the system.

Abstract: The invention relates to a device for explosive forming of workpieces, comprising an ignition chamber and an ignition mechanism, wherein an explosive agent can be ignited at an ignition location in the ignition chamber using the ignition mechanism, and an ignition chamber outlet is provided, to be improved such that the ignition mechanism has a longer service life. The aim is achieved by a device wherein an impact breaker is provided in the propagation path (37) of the detonation wave.

Abstract: With the invention, a method and device for explosive forming of work pieces, in which at least one work piece is arranged in at least one die and deformed by means of an explosive to be ignited, is to be improved, in that an ignition mechanism that is technically simple to handle, is produced with the shortest possible setup time, which permits the most precise possible ignition of the explosive with time-repeatable accuracy. This task is solved by a method and device, in which at least one work piece is arranged in at least one die and deformed by means of an explosive to be ignited, in which the explosive is ignited by means of induction.

Abstract: A laser nanoforming system and method for forming three-dimensional nanostructures from a metallic surface. A laser beam is directed to hit and explode an ablative layer to generate a shockwave that exerts a force on the metallic surface to form an inverse nanostructure of an underlying mold. A dry lubricant can be located between the metallic surface and mold to reduce friction. A confinement layer substantially transparent to the laser beam can confine the shockwave. A cushion layer can protect the mold from damage. A flyer layer between the ablative layer and metallic surface can protect the metallic surface from thermal effects of the exploding ablative layer. The mold can have feature sizes less than 500 nm. The metallic surface can be aluminum film. The dry lubricant can be sputtered Au—Cr film, evaporated Au film or a dip-coated PVP film or other dry lubricant materials.

Abstract: In a method for applying a surface structure to a solid body, a structured surface is placed directly or indirectly onto the surface of the solid body and the structure of this structured surface is reproduced in the surface of the solid body, in that an explosive structured layer is arranged on the surface of the solid body and the structure of the explosive structured layer is explosively disseminated into the surface of the solid body. According to the invention, the surface of the solid body is provided with a surface pre-structure before the actual dissemination, at least in regions, wherein the structure of the explosive structured layer is disseminated on at least one partial region of the surface pre-structure so that the surface structure produced results from overlapping of the surface pre-structure with the explosively disseminated structure.

Abstract: A method of riveting two metal parts through a hole with an electro-hydraulic riveting tool. The electro-hydraulic riveting tool includes a tube that is inserted in the hole and an electrode that is inserted within the tube. A liquid is contained within the tube and the electrode is immersed in the liquid. A stored charge is discharged through the electrode to create a shockwave within the fluid that forms the tube into a rivet structure and creates solid state weld between the rivet flanges and the parts that are joined.

Abstract: Apparatus and methods are disclosed whereby a propellant driven water stream is used in the formation of materials made from high tensile strength alloys. High pressure developed in liquid flowing through a tubular work piece is employed to achieve desired forms. The high pressure results from superposition of compression waves generated in the course of the impact of the liquid by products of propellant combustion.

Abstract: It shall be achieved by the invention that a workpiece for an explosion forming process, which can be inserted into a forming tool and which can be deformed from an initial shape by means of explosion forming, and the explosion forming method are improved such that a satisfactory quality of the workpiece with the desired wall thickness is achieved in a simple manner. This object is achieved by a workpiece and a respective explosion forming method in which the initial shape of the workpiece has at least in some portions a supply of material for the explosion forming process, which is pre-formed compared to adjoining portions or which is provided therewith.

Abstract: Peening provides compression of component surfaces in order to create residual surface compressions to resist crack propagation in components such as aerofoils. Previously peening techniques have had problems with respect to achieving adequate treatment depths, speed of treatment and with respect to effectiveness. By the present method arrangement an electrical conductor in the form of a wire is subject to electrical pulses to cause evaporation and subsequent breakdown with high power ultrasound (HPU) propagation in a volume of dielectric fluid towards a component and so peening. The electrical conductor ensures that there is limited possibility of electrical discharge to the component surface while the positioning of the wire relative to the surface can be adjusted to achieve best effect particularly if reflector devices are utilized to concentrate (HPU) pulse presentation to the component.

Abstract: Through the invention, a closure device for explosive forming with a connection unit movable relative to the explosive forming die between a working position on the die and a rest position is to be configured, so that the explosive forming die can be closed in simple and reliable fashion and, at the same time, the explosion forces supported. This task is solved by a closure device, in which a wedge structure is guided to move on a static holding structure and is motion-coupled to the connection unit, the resulting movement of the connection unit being directed across the movement of the wedge structure.

Abstract: A method for applying a surface structure to a solid body, wherein a structured surface is placed directly or indirectly onto the surface of the solid body and the structure of this structured surface is reproduced in the surface of the solid body, in that an explosive structured layer having the structured surface is arranged on the surface of the solid body and in that the structure of the explosive structured layer is disseminated by ignition of the same in the surface of the solid body; and/or at least one moulded structured layer having the structured surface is arranged on the surface of the solid body and is disseminated in the surface of the solid body by igniting a separate explosive layer, According to the invention the surface of the solid body is provided with a surface pre-structure before the actual dissemination, at least in regions, wherein the structure of the explosive structured layer or the moulded structured layer is disseminated on at least one partial region of the surface pre-struc

Abstract: A tooling method for calibrating a partially formed metal part in an electro-hydraulic forming tool. The method includes loading a partially formed metal part onto a forming surface of a die. The part is then clamped onto the forming surface and the part is pulsed with a high rate energy pulse to overcome a spring-back effect in the part. The EHF calibration tool includes a punch to which a part is held by clamps while a capacitive discharge circuit is discharged through electrodes provided in the tool. Upon discharge of the capacitive discharge circuit through the electrodes, a high rate energy pulse is applied through a liquid to calibrate the part.

Abstract: An electrohydraulic forming (EHF) tool and a method of forming a sheet metal blank in an EHF operation. The tool may include a pair of electrodes and may be filled with a liquid. A high voltage discharge may be produced between the electrodes in a manner that induces a shockwave within the fluid. The shockwave may produce sufficient force within the liquid to form the blank against a die.

Abstract: A material composite has a part made from steel or a titanium-based material and a part made from a copper-based or aluminum-based material. The parts of the material composite are joined by way of an intermediate piece. The intermediate piece likewise comprises a region made from steel or a titanium-based material and a region made from a copper-based or aluminum-based material, which are connected by explosion welding. The parts of the material composite are connected to the regions of the intermediate piece which are in each case of the same type by means of a fusion or diffusion welding process.

Abstract: An electrohydraulic forming (EHF) tool and a method of forming a sheet metal blank in an EHF operation. The tool may include a pair of electrodes and may be filled with a liquid. A high voltage discharge may be produced between the electrodes in a manner that induces a shockwave within the fluid. The shockwave may produce sufficient force within the liquid to form the blank against a die.

Abstract: Methods for making skin panels suitable for use in aircraft structures and fuel tank structures, such as fuselages and reusable launch vehicle propellant tanks. A first method includes the following steps: machining a starting plate to a final part geometry; and explosive forming the machined plate to at least one of a uniaxial curvature and a biaxial curvature. A second method includes the following steps: explosive forming a starting plate to at least one of a uniaxial curvature and a biaxial curvature; and machining the curved plate to a final part geometry. Accordingly, the invention enables making integrally stiffened unitized axial load carrying skin panels that are either uniaxially or biaxially curved.

Abstract: A method of connecting a first pipe to a second pipe having an end part fitting into an end part of the first pipe, comprising arranging the end part of the second pipe within the end part of the first pipe, arranging a sleeve of a deformable material between said end parts, and radially expanding the end part of the second pipe towards the end part of the first pipe so as to bias the sleeve between said end parts.

Abstract: An apparatus for forming a generally planar metal plate into a dish with a three-dimensional pattern is provided. The apparatus comprises a mold having a forming surface with a contour corresponding to said three-dimensional pattern, and having edges corresponding to boundaries of the dish, which edges are defined by side walls essentially perpendicular to the forming plane; a forming device comprising a fluid basin and pairs of electric discharge members within the fluid and having an opening facing the mold to allow transmission of a pressure wave from the fluid to the metal plate; and an electric discharge circuitry for discharging a short and intense electric current through the pairs of electric discharge members generating an electric spark or breakdown within the fluid to yield formation of plasma, vapor or both.

Abstract: Methods and apparatus employing an ultra high-pressure fluid pulse to perform metal working operations, including joining and cold working. In one application, an ultra high-pressure fluid pulse is directed into a hollow rivet that is seated within an orifice formed in two metal sheets, causing the fastener to expand outwardly, in an interference fit with the orifice that joins the metal sheets together. The ultra high-pressure fluid pulse can alternatively be applied to the metal sheets to plastically deform them into a cavity to form a clinch fastener joint. Further, the ultra high-pressure fluid pulse is usable to plastically deform the interface between stacked metal sheets or other components into surface features that are provided on one of the sheets, to form a mechanical interlock.

Abstract: An aluminum-thermoplastic composite surface structure. A sheet of aluminum is formed to a single-sided mold by heating the sheet and applying a ramp of gas pressure. A thermoplastic resin is heated and microballons are added to the resin to lower the viscosity of the resin, which is applied through a nozzle in a hexagonal pattern on the formed aluminum sheet. Upon cooling, the composite resin forms a honeycomb pattern. The hexagonal pattern transitions to a columnar pattern and a backing layer of aluminum sheet is gas pressure formed to the resin composite. Gas forming of the aluminum sheet results in aspect ratios of up to 0.6, and the sheet maintains a clean surface that bonds to the applied resin.