Abstract:
A method and apparatus for forming and consolidating organic matrix composites. An organic matrix composite panel comprising laid-up prepregs is placed between sheets of a susceptor material that is susceptible to inductive heating to form a workpiece. The resulting workpiece is placed within upper and lower dies formed of a material that is not susceptible to inductive heating. An induction coil embedded within the dies is energized and inductively heats the susceptor sheets surrounding the panel. The sheets in turn conductively heat the organic matrix composite panel. A pressure zone between the workpiece and one of the dies is pressurized to form the workpiece to the contour of a forming surface on one of the dies. The pressure in the pressure zone is maintained on the workpiece until the organic matrix composite panel is fully consolidated and formed.
Abstract:
Multisheet SPF parts with braze joints at selected locations are produced with improved energy efficiency and at lower cost by heating the multisheet pack to its superplastic forming range below the melting point of the braze alloy, superplastically forming the pack to define braze joints having unmelted braze alloy; increasing the temperature to the braze temperature of the braze alloy, and cooling the pack below the superplastic range to freeze the braze alloy in the braze joint.
Abstract:
A process for consolidating a composite material comprises the steps of forming a workpiece including a matrix interspersed with fibers, supporting the workpiece by an electrically conductive support, inductively heating the support and thereby conductively heating the workpiece, and applying pressure to the heated workpiece. We apply the pressure by passing the support and workpiece through spaced rolls. To keep the workpiece from sticking to the support (i.e., the mandrel), we use boron nitride as a release agent.
Abstract:
A fixed coil induction heater produces quality thermoplastic fusion welds in prefabricated resin composite parts. A susceptor along a bondline between parts aligns with the induction coil segments of a solenoid induction coil along the centerline of the coil. Energizing the coil heats the susceptor to form the weld at the bondline. For this operation, our induction heating workcell uses complementary dies that define a central cavity with an oval pattern of induction coil segments roughly conforming to the shape of the cavity and surrounding all faces of the cavity where we position the preform composite parts and susceptor.
Abstract:
Apparatus and method for superplastic forming. The workpiece is held between a pair of dies that are electrically and thermally nonconductive, and is heated inductively by a coil embedded within the dies. The dies are formed of a material that is substantially transparent to inductive heating. A plurality of electrical conductors are embedded within the die. The electrical conductors are interconnected into one or more electrically conductive coils that surround the workpiece. The electrical conductors are used to produce a time varying magnetic field that is used to heat the workpiece. In one embodiment, the workpiece is a composite material that is susceptible to inductive heating. The composite material includes an electrically conductive material. The time varying magnetic field heats the electrical conductive material, thereby heating the workpiece. The die also includes a forming surface having a shape corresponding to a desired shape of the workpiece. A pressure differential is created between the first and second sides of the workpiece to deform the workpiece to the shape of the forming surface.
Abstract:
A process for consolidating a composite material comprising the steps of forming a workpiece including a matrix interspersed with fibers, supporting the workpiece by an electrically conductive support, inductively heating the support and thereby conductively heating the workpiece, and applying pressure to the heated workpiece.
Abstract:
The invention is related to a continuous coating apparatus for applying molten metal on a metal sheet or tape. The apparatus has an annular cylinder having an open lower section extending to a substantially closed upper section. An axle is mounted in the lower section normal to the cylinder axis, and a spool is mounted on the axle. A pair of tubes are mounted parallel to the cylinder axis inside the cylinder on oppositely facing surfaces so that a tape extending around the spool towards the upper section extends through the tubes.
Abstract:
FIRST AND SECOND LASERS HAVING DIFFERENT CHARACTERISTICS ARE FOCUSED ON THE SAME SPOT SO THAT THE DIFFERENT CHARACTERISTICS CAN BE EMPLOYED ON THE SAME SPOT. FOR EXAMPLE, A SOLID-STATE LASER CAN MELT A SPOT ON A WORKPIECE, AND A FLUID-STATE LASER CAN MAINTAIN THE LIQUID SPOT. A POSITIONING AND FEEDING TABLE IS PREFERABLY EMPLOYED TO LOCATE THE SPOT ON THE WORKPIECE AT WHICH THE COMBINATION OF THE LASERS IS ACTIVE.