Rolls-royce Corporation

Brian Richardson

John O Fowler

Michael Green

John J Gilkinson

A method of diffusion bonding three metal work pieces to form a fan blade, where each workpiece has a flat surface and an excess portion larger than a predetermined size needed to produce a finished fan blade; longitudinally extending slots are provided to interconnect the flat surfaces of the excess portions of the work pieces; the work pieces are assembled into a stack with the flat surfaces in mating abutment and the stack is evacuated from one end of the stack through the slots; heat and pressure are applied across the thickness of the work pieces to diffusion bond the work pieces together to form an integral structure; the excess portions with the slots are then removed.

Method of manufacturing an article by diffusion bonding

In a method of manufacturing a hollow component metallic sheets are diffusion bonded together except where a stop off pattern is applied to the surfaces of the sheets. A gas channel is accommodated in the thickness of the sheets for the entry of pressurised gas under superplastic forming conditions to produce the hollow component. The material defining the gas channel is locally deformed by forging to reduce the height of the gas channel in order that a subsequent fusion welding pass over the deformed area defining the gas channel hermetically seals the gas channel.

Hollow component manufacture

A plurality of workpieces are assembled into a stack. Two of the workpieces are machined on one surface at predetermined positions from the edges of the workpieces. The workpieces are stacked so that the machined surfaces of the workpieces face away from each other. Two workpieces are provided with a stop off material on one of their surfaces to prevent diffusion bonding at predetermined positions. The edges of the workpieces are welded together and a pipe is welded to the stack to interconnect with the stop off material to form a sealed assembly. The workpieces are diffusion bonded together. The integral structure formed is heated and opposite ends of the integral structure are twisted relatively to contour the integral structure to a predetermined shape. The integral structure is heated and the machined portions on the workpieces are isothermally forged and then the twisted integral structure is internally pressurised to superplastically form one workpiece to produce an article, eg a fan blade.

Method of manufacturing an article by superplastic forming and diffusion

A plurality of titanium sheets are assembled into a stack. At least one of the sheets is provided with a stop off material on one of its surfaces to prevent diffusion bonding at predetermined positions. The edges of the sheets are welded together and a pipe is welded to the stack to interconnect with the stop off material to form a sealed assembly. The assembly is heated and externally pressurized to diffusion bond the sheets together. The integral structure so formed is heated and opposite ends of the integral structure are twisted relatively to contour the integral structure to a predetermined shape. The integral structure is internally pressurized to break the adhesive bonds. The integral structure is heated and internally pressurized to superplastically form one sheet to produce an article, e.g. a fan blade.

A plurality of workpieces are assembled into a stack. Two of the workpieces are machined on one surface at predetermined positions from the edges of the workpieces. The workpieces are stacked so that the machined surfaces of the workpieces face away from each other. Two workpieces are provided with a stop off material on one of their surfaces to prevent diffusion bonding at predetermined positions. The edges of the workpieces are welded together and a pipe is welded to the stack to interconnect with the stop off material to form a sealed assembly. The workpieces are diffusion bonded together. The integral structure formed is heated and opposite ends of the integral structure are twisted relatively to contour the integral structure to a predetermined shape. The integral structure is heated and the machined portions on the workpieces are isothermally forged and then the twisted integral structure is internally pressurized to superplastically form one workpiece to produce an article, e.g. a fan blade.

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Lancashire, United Kingdom

Brian Richardson