The Boeing Company

David Howard Gane

Matthew G Kistner

Jeffrey D Will

Frederick W Buldhaupt

Gary Robert Weber

Daniel James Kane

Terry C Tomt

Ricole Allison Johnson

Ryan J Glamm

Peter D Verge

Bruce M Burg

Donald Lloyd Conaway

Azzréal Pugh

Robert M Starowski

Jeffrey N Repsumer

Anthony David Martinez

Justin Michael Poirier

Lonny D Walz

Duane Michael Hill

A method for manufacturing a part including steps of (1) casting an ingot, (2) scalping the ingot to yield a scalped ingot, (3) homogenizing the scalped ingot to yield a homogenized ingot, (4) breakdown of the homogenized ingot to yield a slab, (5) rolling the slab to yield a rolled aluminum material, (6) annealing the rolled aluminum material to yield an aluminum starting material, (7) cold working the aluminum starting material to obtain an aluminum cold worked material, and (8) forming the part from the aluminum cold worked material.

Method for manufacturing anodized aluminum alloy parts without surface discoloration

A method for manufacturing a part including steps of providing an aluminum starting material, wherein the aluminum starting material is in an anneal temper, cold working the aluminum starting material to obtain an aluminum cold worked material, and forming the part from the aluminum cold worked material.

A metal part is hot formed by placing a metal part blank on a forming tool and installing a fabric cover over the forming tool, overlying the metal part blank. The fabric is at least partially wrapped around the metal part blank. The metal part blank is heated to a temperature sufficient to allow forming of the metal part blank. Forming pressure is applied to the metal part blank that conforms the metal part blank to the forming tool by tensioning the fabric.

Method and apparatus for hot forming metal parts

A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack. An envelope gas fitting is placed between the face sheets and is welded in place while seal welding around the entire peripheral edges of the face sheet and the core pack to produce a sealed envelope pack enveloping the core pack, with gas fittings into the core pack and into a face sheet zone between the face sheets and the core pack. A gas supply tube from the gas supply control system is connected to each of the fittings and air and moisture is purged from the packs by flushing with dry argon. The packs are pressurized to a low pressure with argon to maintain separation of the sheets while heating to prevent premature diffusion bonding. The full pack is placed in an internal cavity of a heated die and is raised to superforming temperatures. Forming gas is injected through the fittings at a forming pressure sufficient to inflate the envelope pack to the interior walls of the cavity, and inflate the core pack to the envelope pack and to diffusion bond the face sheets to the core sheets. The die is opened and the formed pack is removed from the die while still at an elevated temperature.

Multisheet sandwich structures with throughholes

A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can from under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack. An envelope gas fitting is placed between the face sheets and is welded in place while seal welding around the entire peripheral edges of the face sheet and the core pack to produce a sealed envelope pack enveloping the core pack, with gas fittings into the core pack and into a face sheet zone between the face sheets and the core pack.

Method for making multisheet metal sandwich structure with throughholes

Multisheet metal sandwich structures

Elevated temperature envelope forming includes enclosing a part blank and form tool within an envelope sealed against the atmosphere, heat treating the combination while forming pressure holds the envelope and part against the form tool, and allowing part cool down to occur in an inert atmosphere with forming pressure removed. The forming pressure is provided by evacuating the envelope and may be aided by differential force applied between the envelope and the form tool.

Elevated temperature envelope forming

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Seattle, WA, United States of America

David Howard Gane