The Boeing Company

Frederick W Buldhaupt

Matthew G Kistner

Jeffrey D Will

David Howard Gane

Robert David Briggs

Gary W Coleman

John R Fischer

Tristan E Lee

Leo E Dondlinger

Catherine J Parrish

Provided is a laser-weld manufacturing method. The method includes: providing a first component and a second component that are separated from one another by a gap, the gap having a depth and a width and at least one of the first component and the second component having a sacrificial edge-tab; exposing the sacrificial edge-tab to laser energy, the laser energy being sufficient to melt at least a portion of the sacrificial edge-tab; forming a melt-pool in the gap between the first component and the second component, the melt-pool including material from the melted portion of the sacrificial edge-tab; and solidifying the melt-pool to form a weld that joins the first component and the second component together.

Edge preparation for laser welding

Methods of forming a weld joint using rotating shielding devices are disclosed. To form the weld joint, the rotating shielding device may be moved continuously along a seam formed between two structures being welded, so as to avoid having to remove the rotating shielding device during, for example, welding around corners. In this manner, disclosed methods of welding may improve efficiency of techniques such as vertical welding. During welding, rotating shielding devices may be coupled to a shielding gas supply, such that the shielding gas exits through an outlet formed in an axle of the rotating shielding device as the device is rotated and moved along the seam. The rotating shielding device may contain a plurality of partitions defining one or more chambers, the partitions and chambers being positioned between spaced-apart rotating portions, with the rotating shielding device configured to direct the shielding gas towards the weld pool during welding.

Methods of welding using rotating shielding devices

Rotating shielding devices for supplying a shielding gas to a weld pool as a weld joint is formed may be configured to be moved continuously along a seam formed between two structures being welded, so as to avoid having to remove the rotating shielding device during, for example, welding around corners. In this manner, rotating shielding devices and methods of welding may improve efficiency of welding techniques such as vertical welding. In operation, rotating shielding devices may be coupled to a supply of shielding gas, which may exit through an outlet formed in an axle of the rotating shielding device. The rotating shielding device may contain a plurality of partitions defining one or more chambers, the partitions and chambers being positioned between spaced-apart rotating portions, with the rotating shielding device configured to direct the shielding gas towards the weld pool during welding.

Rotating shielding devices

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

A superplastically formed, diffusion bonded sandwich structure having integral metal hardpoints, made by joining two superplastic metal core sheets together into a core pack by welding or diffusion bonding along a pattern of lines which form junction lines between the core sheets when the pack is inflated by gas pressure at superplastic temperatures. Face sheets are laid under and over the core pack and metal inserts are interposed between the face sheets and the core. All of the sheets in the pack are sealed together around an outside peripheral edge to create a gas tight envelope. The pack is heated to superplastic temperatures in a cavity in a die, and the top and bottom face sheets are diffusion bonded to top and bottom surfaces of the metal insert by application of heat and pressure from top and bottom inner surfaces of the die cavity. While at superplastic temperatures, the pack is inflated by gas pressure against inside surfaces of a die to form an expanded metal sandwich structure having integral webs and integral hardpoints formed by the metal insert. After forming, the gas pressure is reduced to near atmospheric, the die is opened and the part is removed from the die.

Growing community of inventors

South Prairie, WA, United States of America

Frederick W Buldhaupt