Spirit Aerosystems, Inc.

Gerald E Hicks

Rahbar Nasserrafi

Craig M Clasper

Kerrick Robert Dando

Michael A Walker

David E Jakstis

Mark Anthony Wadsworth

Kevin Lyle Obrachta

Darrell A Wade

Linda Cadwell Stancin

LaVerne L Waalkes

Micheal A Walker

A method of forming a metal matrix composite component includes positioning a preform including an electrically non-conductive fibrous material in a shaping tool. The fibrous material is pre-coated. The method includes flowing a molten metal comprising zinc into the shaping tool so that at least a portion of the preform is enveloped by the molten metal to form the metal matrix composite component; and cooling the metal matrix composite component.

Method to produce low-cost metal matrix composites for industrial, sports, and commercial applications

A method of manufacturing a complex-shaped composite part, including the steps of applying a metallic sheath around a composite laminate workpiece and applying an electric current through the metallic sheath to heat the workpiece. The metallic sheath may be sealed around the composite laminate workpiece, with air or atmosphere evacuated therefrom. The method also includes shaping the workpiece in the metallic sheath into a complex-shaped composite part while it is being heated. The shaping can be performed between two ceramic dies or using other techniques for forming complex shapes and curvatures into the workpiece. The method then may include cooling the complex-shaped composite part and removing the metallic sheath from the complex-shaped composite part. This method minimizes cycle times and reduces breakage of fiber reinforcement of the composite laminate. The method also helps avoid tearing, buckling, or wrinkling of the workpiece during formation via the structural support provided.

Method of forming composites by joule heating of enveloping metallic sheets

A method for heat-treating a titanium alloy, such as Ti-6Al-4V. The method may occur after or include a step of forging the titanium alloy such that localized, highly deformed grains are formed in the titanium alloy. Then the method may include steps of recrystallization annealing the titanium alloy by heating the titanium alloy to a temperature in a range between 30&#xb0; F. to 200&#xb0; F. below beta transus of the titanium alloy for 1 hour to 6 hours and then furnace cooling of the titanium alloy to 1200&#xb0; F. to 1500&#xb0; F. at a rate of 50&#xb0; F. to 500&#xb0; F. per hour. Following the recrystallization annealing, the method may include beta annealing the titanium alloy. These steps may be performed in a single heat treating cycle.

Method to prevent abnormal grain growth for beta annealed Ti&#x2014;6AL&#x2014;4V forgings

Aluminum alloys are provided that can comprise boron and vanadium and high amounts of titanium and zirconium. The aluminum alloys described herein can exhibit superior tensile properties at both room temperature and elevated temperatures and still maintain desirable ductility. The aluminum alloys can be used in applications where resistance to fatigue and breakdown at elevated temperatures is desirable, which includes applications in the aerospace and aeronautical fields.

Aluminum-copper alloys with improved strength

Method to prevent abnormal grain growth for beta annealed TI-6AL-4V forgings

An aircraft thrust reverser inner wall and method of manufacturing the same. The aircraft thrust reverser inner wall may include a face sheet, a perforated back sheet, and a core sandwiched between the face sheet and the perforated back sheet. The face sheet may have an inner face sheet surface and an outer face sheet surface, and the core may have an inner core surface, an outer core surface, and a plurality of cell walls extending therebetween. An electro-depositable material may be applied, via electrodeposition, in a substantially continuous layer over the outer core surface, the cell walls, and the outer face sheet surface, thus bonding the face sheet and core together. The perforated back sheet may be attached to the core at the outer core surface, and a conductive coating may be applied to the inner face sheet surface.

Hybrid thrust reverser inner wall for aircraft engines

Aluminum-based alloys for casting or wrought processing having improved combinations of properties, including improved high temperature strength, are provided. The alloys generally comprise copper, magnesium, silver, and titanium, along with scandium and/or cobalt. Zirconium, zinc, and/or vanadium may also optionally be present in the alloy. When cobalt is present in the alloy, nickel may also optionally be present. Cast and wrought products, as well as methods of making the same using the alloys, are also disclosed.

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Wichita, KS, United States of America

Gerald E Hicks