公开(公告)号：US20240308147A1

公开(公告)日：2024-09-19

申请号：US18606959

申请日：2024-03-15

Applicant: Spirit AeroSystems, Inc.

Inventor： Kerrick Dando

IPC: B29C65/36 ,  B29C35/00 ,  B29C35/16 ,  B29C65/00

CPC classification number: B29C65/3668 ,  B29C35/002 ,  B29C35/16 ,  B29C66/7212 ,  B29C2035/1616

Abstract: Disclosed are methods and apparatus for use in composite manufacturing, to facilitate cooling of composite parts. The methods and apparatus disclosed are of particular use in thermal joining methods. A magnetic field is applied to a magnetocaloric material to induce a magnetic phase change. Heat is exhausting heat from the magnetocaloric material while the magnetic field is applied and, when the magnetic field is disapplied, heat is flowed from the composite assembly to the magnetocaloric material, reversing the magnetic phase change and cooling the composite part. An induction coil for inductively heating the composite part may be used to apply the magnetic field.

公开(公告)号：US20240300195A1

公开(公告)日：2024-09-12

申请号：US18119205

申请日：2023-03-08

Applicant: Spirit AeroSystems, Inc.

Inventor： Kerrick Dando ,  Rahbar Nasserrafi ,  Mark Anthony Wadsworth ,  Gerald Hicks

IPC: B29C70/54 ,  B29C70/44

CPC classification number: B29C70/544 ,  B29C70/44 ,  B29C70/545

Abstract: A method of manufacturing a complex-shaped composite part, including the steps of applying a metallic sheath around a composite laminate workpiece and applying an electric current through the metallic sheath to heat the workpiece. The metallic sheath may be sealed around the composite laminate workpiece, with air or atmosphere evacuated therefrom. The method also includes shaping the workpiece in the metallic sheath into a complex-shaped composite part while it is being heated. The shaping can be performed between two ceramic dies or using other techniques for forming complex shapes and curvatures into the workpiece. The method then may include cooling the complex-shaped composite part and removing the metallic sheath from the complex-shaped composite part. This method minimizes cycle times and reduces breakage of fiber reinforcement of the composite laminate. The method also helps avoid tearing, buckling, or wrinkling of the workpiece during formation via the structural support provided.

公开(公告)号：US20240342975A1

公开(公告)日：2024-10-17

申请号：US18134757

申请日：2023-04-14

Applicant: Spirit AeroSystems, Inc.

Inventor： Kerrick Dando ,  Mark Anthony Wadsworth ,  Rahbar Nasserrafi

IPC: B29C51/14 ,  B29C51/22 ,  B29C51/26

CPC classification number: B29C51/14 ,  B29C51/22 ,  B29C51/265 ,  B29K2101/12 ,  B29K2705/02 ,  B29K2705/08

Abstract: An apparatus for roll forming thermoplastic composites comprises a plurality of thermoplastic composite material spools, a plurality of thermoplastic composite material rollers, a plurality of sheet metal spools, a plurality of welding rollers, an oven, a forming roller, a pair of pinch rollers. The thermoplastic composite material spools retain plies of thermoplastic composite material. The plies flow through the thermoplastic composite material rollers to form a layup. The sheet metal spools retain metal sheets. The metal sheets and the layup flow through the welding rollers to form a metal composite material laminate. The oven heats the metal composite material laminate. The forming roller imparts a curvature to the metal composite material laminate. The pinch rollers receive the metal composite material laminate from the forming roller, pull the metal composite material laminate, and output the metal composite material laminate in a heated and compressed state.

公开(公告)号：US20240337005A1

公开(公告)日：2024-10-10

申请号：US18131549

申请日：2023-04-06

Applicant: Spirit AeroSystems, Inc.

Inventor： Rahbar Nasserrafi ,  Kerrick Dando ,  Gerald Hicks

IPC: C22C47/08 ,  B22D17/00 ,  B22D18/06 ,  B22D19/14 ,  B22D30/00 ,  C22C47/04

CPC classification number: C22C47/08 ,  B22D17/00 ,  B22D18/06 ,  B22D19/14 ,  B22D30/00 ,  C22C47/04

Abstract: A method of forming a metal matrix composite component includes positioning a preform including an electrically non-conductive fibrous material in a shaping tool. The fibrous material is pre-coated. The method includes flowing a molten metal comprising zinc into the shaping tool so that at least a portion of the preform is enveloped by the molten metal to form the metal matrix composite component; and cooling the metal matrix composite component.