The Boeing Company

Mcdonnell Douglas Corporation

David R Bolser

Timothy Joseph Trapp

David P Heck

Ryan Lee Hanks

Keith A Young

Kevin G Waymack

Ricky L Martin

Karl F Graff

Allen H Fischer

Wallace J Lewis

A metallurgically formed fluid circuit joint includes a hollow fitting (), a tubular conduit (), and a metallurgically formed tube/fitting mesh (). The tube/fitting mesh () includes a fitting portion of the hollow fitting () and a tube portion of the tubular conduit () that is electromagnetically formed with the fitting portion.

Electromagnetic pulse welding of fluid joints

Machined structural members and methods for forming the same are disclosed. In one embodiment, a structural member includes a web portion that extends in a first direction that includes a non-planar portion, and a first flange portion coupled to the web portion that extends in the first direction. A second flange portion is coupled to the web portion that also extends in the first direction. The first flange portion and the second flange portion are spaced apart in a second direction that is approximately perpendicular to the first direction. The web portion and the first and second flange portions are integrally formed as a unitary, monoblock component.

Method for machining a structural member having an undulating web

An aluminum tubular unit for long-term, leak-free storage of fluids is formed in which an aluminum cap is ultrasonically welded to an end of the aluminum tube. The ultrasonic weld is formed from a device capable of producing a torsional vibration pattern. The ultrasonic welding of the cap to the tube eliminates the use of seals and pins to seal the cap to the tube and further eliminates the need for having a hole in the cap to mechanically couple the respective end cap to the cylindrical tube. Furthermore, since ultrasonic welding does not generate significant heat, highly volatile and flammable fluids can be present within the tube when the caps are ultrasonically welded to the cylindrical body. In addition, one or more fins used may also be welded to the outside diameter of the cylindrical body using a related ultrasonic welding process.

Aluminum end caps ultrasonically welded to end of aluminum tube

A method for coating and an associated assembly including such a coating are provided. The assembly includes a workpiece defining a weld portion, such as a friction weld joint and a heat affected zone. A coating is disposed on the weld portion to at least partially cover the weld portion, thereby providing enhanced corrosion resistance to the workpiece.

Aluminum coating for the corrosion protection of welds

A zone of corrosion-resistant material covering a friction stir welded joint surface is provided by applying a layer of corrosion-resistant material over one or both surfaces of the workpieces being joined so that the layer covers at least the weld zone which will be rendered plastic during a friction stir welding operation. The corrosion-resistant material layer is contacted by the friction stir welding tool, and the tool causes shearing and plastic flow of the corrosion-resistant material along the surface of the welded joint. The corrosion-resistant material thus metallurgically bonds with portions of the plasticized metal so as to form a corrosion-resistant zone protecting the welded joint from exposure to corrosive environments.

Integral corrosion protection of friction-welded joints

A method of eutectic bonding of a stainless steel fine mesh screen directly to a surface of a titanium member by cleaning the surfaces of the screen and member and subjecting those parts to pressure to secure an intimate contact and heat to effect the bonding thereof without destroying the integrity of the screen and adversely affecting the wicking action of the screen which is of prime importance.

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Florissant, MO, United States of America

David R Bolser