Abstract:
The present invention provides a method of superplastically forming at least two sheets of superplastically formable material to form a three dimensional article, the sheets being joined together along diffusion bonds (12) to form discrete cells (16) and wherein at least one gas path (18) is provided through the bond between cells; the method involves heating the sheets to a temperature at which they exhibit superplastic properties and injecting a gas between the sheets to expand the cells, the gas paths (18) allowing the injected gas to pas from cell to cell. According to the invention, the edges of the gas paths are locally heated (22), e.g. by laser heat treatment, to cause a change in the microstructure of the sheets in the heat-treated edge areas, which reduces the flow resistance of the edges under superplastic forming conditions as compared with the rest of the sheets and thereby reduces the propensity of the diffusion bonds (12) bordering the gas transfer holes to peel apart under the forces of the inert gas exerted on the sheets at the gas transfer paths (18).
Abstract:
A method of forming a plurality of large diameter tubular titanium components each suitable for use as a portion of a jet engine exhaust tube, the method includes the step of forming a large diameter titanium tube (1), and then subjecting the tube to a superplastic forming process. The superplastically formed titanium tube is then cut at at least one selected location (14, 15) along its length to sever it into at least two large diameter tubular titanium components (11, 12, 13). The titanium components (11, 12, 13) are particularly suitable for assembly to form an adjustable exhaust jet pipe for a VTOL aircraft.
Abstract:
A large tubular sheet metal part (13) which is to be hot formed in a press is preheated in a portable furnace (17) and dropped from the furnace onto the punch portion (14) of the press tool outside the press. The punch portion (14) with the heated sheet metal part (13) supported on it is then translated into the press for the pressing step. A similar portable furnace which incorporates electric induction coils to heat a workpiece may be adapted for superlastic forming sheet metal.
Abstract:
A method of forming an elongated tubular blank into a tubular structural component having a predetermined outer configuration, the method comprising: providing a shape imparting shell (66) from a low permeability, rigid material which includes an inner surface defining the predetermined shape, plugging the open ends of the tubular blank (A), placing the plugged blank into the shell, and forming the tubular blank into the tubular component by inductively heating axial portions (10, 12) of the blank by axially spaced conductors adjacent the shell while or before forcing gas at a high pressure into the plugged blank until the blank conforms to at least a portion of the inner surface of the shell to form the structural component.
Abstract:
Sheet materials are superplastically formed and optionally diffusion bonded into structures, by directly electrically resistance heating the sheets and forming them with a controlled gas-mass flow while the dies (362) in which they are formed may remain relatively cool. The dies include electrodes and thermocouples placed therein, and gas interface ports that connect to the sheets to be formed to allow rapid formation of structures. Some of the gas interface ports may become sealably attached to the part during the formation process so that the structures may be removed from the dies hot, thus allowing a high die throughput.
Abstract:
A titanium gas injection tube (18) is located within a counterbore (16) in the blade (10) halves which are to be bonded and formed. An internal stainless steel sleeve (24) is placed in the counterbore inside the titanium tube to resist bonding forces. An external stainless steel sleeve (28) is placed around the tube to resist gas pressure forces.
Abstract:
Process for the manufacture of assemblies consisting of two formed and glued pieces. Both pieces (1 and 3) are disposed on a punch and die (2 and 4) provisionally separated in order to introduce sufficient pressure to hot form them. The punch and die are then brought together so that the surfaces previously coated with adhesive are face to face and contact one another. The invention is essentially advantageous in that no manual intervention is required.
Abstract:
A forming die (13) which includes a die cavity (19) contains a forming blank (17) composed of a metallic alloy having superplastic properties. The forming pressure in a pressurized space (18) adjacent the forming blank (17) is regulated by a pressure regulator (23). The volume of the die cavity (19) is determined, as is the mass of gas initially contained in the die cavity (19) at the beginning of the forming cycle. The total forming time is empirically determined. The average gas mass flow rate that will be exhausted from the die cavity (19) is calculated by dividing the total mass of gas initially contained in the die cavity (19) by the total forming time. A gas mass flow meter (33) fluidly communicates with the die cavity (19) and measures the mass flow rate of the gas (35) displaced by the forming blank (17) and exhausted from the die cavity (19). The gas mass flow meter (33) is continuously monitored during the forming cycle or a gas mass flow rate signal is fed back to the pressure regulator (23). The forming pressure is regulated by the pressure regulator (23) so that the gas mass flow rate exhausted from the die cavity (19) approximates the predetermined average gas mass flow rate.
Abstract:
Each of the metallic units (1) has a concave portion (5) bounded by a peripheral edge (7) which has a predetermined shape. The apparatus includes an upper member (11) and a lower member (13) and a tool (41) is adapted to be mounted on the upper or lower member (11, 13). The tool (41) comprises a wall-like structure (51) having a bottom edge (53) which defines a shape corresponding with the predetermined shape. The upper member (11) and lower member (13) are arranged to be movable relative one to the other, and a workpiece (1) is placed between the two members (11, 13) and the members (11, 13) are brought together until the bottom edge of the tool (41) abuts the workpiece (1) so that the tool (41) and workpiece (1) are clamped together in airtight engagement. Air under pressure is applied under the workpiece (1) to form the workpiece into a concave shape.
Abstract:
In one example, a metal-plastic composite structure for an electronic device is described, which includes a micro-arc oxidized metal substrate and at least one plastic film disposed on the micro-arc oxidized metal substrate using a superplastic forming process.