The Boeing Company

Mcdonnell Douglas Corporation

Ford Global Technolgoies, LLC

Northwestern University

University of Missouri

Rajesh Talwar

Jian Cao

Zhiyong Cedric Xia

Qian Jane Wang

Pinzhi Liu

Donald J Grzina

Tiffany Davis Ling

Richard J Lederich

Ricky L Martin

John A Baumann

David R Space

Stephen M Trent

David C Van Aken

James M Ogonowski

Rigoberto Perez

Barton Moenster

Hülya Cebeci

A compact, lightweight, low power aircraft air filtration and VOC removal unit enables the removal of VOCs from cabin air in a passenger aircraft. A plurality of baffles having air flow-through airflow spaces are spaced apart along a duct. UV LEDs are mounted on the interior sides of the outermost baffles, and on both sides of all interior baffles. A filter module is disposed between pairs of baffles, and spaced from the baffles sufficiently to illuminate the entirety of both sides. Each filter modules comprises a plurality of filters. The filters are selected from a coarse foam, a fine foam, or a fused quartz filament felt. Each filter is loaded with a catalyst including one or more of AEROXIDE&#xae; P25, other pure titanium dioxide (TiO), iron-doped TiO, carbon-doped TiO, and combinations thereof. The catalysts on the filters, under UV illumination, chemically reduce VOCs in the airflow to non-VOC molecules.

Aircraft air purification and volatile organic compounds reduction unit

A forming tool stamps sheet metal blanks into a desired shape. A contoured surface is defined for the forming tool so that respective portions of the metal blank flow over the contoured surface during forming. An intrinsic material flow pattern resulting from the contoured surface is compared to a desired flow in order to identify regions of the contoured surface having an insufficient flow that creates areas in the formed metal blank receiving less than a desired amount of metal. A surface microtexture is applied onto the contoured surface in a pattern selected to increase metal flow along the identified regions by providing a coefficient of friction in the identified regions that is reduced relative to adjacent regions of the contoured surface.

Forming tools having textured surfaces

A manufacturing method forms components having a desired shape. A contoured surface is defined for a forming tool for forming a metal blank into the desired shape, wherein respective portions of the metal blank flow over the contoured surface during forming. An intrinsic material flow pattern resulting from the contoured surface is compared to a desired flow in order to identify regions of the contoured surface having an insufficient flow that creates areas in the formed metal blank receiving less than a desired amount of metal. A surface microtexture is applied onto the contoured surface in a pattern selected to increase metal flow along the identified regions by providing a friction in the identified regions that is reduced relative to adjacent regions of the contoured surface.

A cutting tool comprising first and second surfaces that intersect at an edge, wherein the first surface (e.g., a rake face, a flank surface or a margin) has a textured region comprising a multiplicity of recesses each having a length greater than its width. The recesses are distributed in a pattern comprising rows of recesses arranged lengthwise along respective lines with spaces between neighboring recesses. The recesses of one row are offset from the recesses of the next row. Each recess of the one row having one end portion that overlaps with an end portion of one recess in the next row and another end portion that overlaps with an end portion of another recess in the next row. The recesses are generally parallel to the edge.

Cutting tools with textured surfaces

Fuselage skins of aircraft are joined using friction stir welding. A strip of cladding is removed from the skins along an abutment between the skins before the skins are welded in order to prevent the cladding from interfering with the welding process. The cladding is replaced after the welding is completed.

Joining fuselage skins using friction stir welding

A method for weldbonding at least two work-pieces together includes applying an adhesive to a first surface of a first work-piece, and bringing the first surface of the first work-piece into contact with a surface of a second work-piece. The first work-piece and second work-piece are then friction stir or friction stir spot welded together, and the adhesive is cured. The use of bonding tools to maintain the two work-pieces together during curing of the adhesive is eliminated.

Method for forming a weldbonded structure

A method of friction stir welding joints with shims and an associated structural assembly is provided. The structural assembly includes one or more skin members that are disposed and friction stir welded to a substructure. A shim is disposed in a space defined by the other members of the assembly, e.g., between adjacent skin members or between a skin member and the substructure. The shim can be friction stir welded to the other members. That is, the adjacent skin members can be connected via the shim, and/or the skin members can be connected to the substructure via the shim. In some cases, the skin members and the substructure are relatively stiff, and the shim substantially fills the space to reduce flexing of the members during the friction stir welding operation.

Friction stir welding of joints with shims

Method for joining at least two adjoining work-pieces by friction stir and/or friction stir spot welding

A method of repairing a crack () in a component (). The method includes preparing a surrounding surface () of the crack () for repair and welding a first portion () of the component () on a first side () of the crack () to a second portion () of the component () on a second side () of the crack () to form a fused crack area (). The method may also include applying a patch () over the fused crack area () for additional strength.

Method of repairing a crack in a component utilizing friction stir welding

A sealant for a weld joint and an associated weld joint and method are provided. The sealant includes aluminum and germanium and is characterized by a melting temperature that is lower than the melting temperature of the structural member that is joined. The sealant, which is disposed between faying surfaces of the structural members, can fill the spaces between the structural members to prevent the entry of chemicals, moisture, debris, and other substances, thereby reducing the likelihood of corrosion of the joint or structural members at the interface. Further, the sealant can be diffusion bonded to the faying surfaces, for example, by the heat generated during the joining process.

Method and sealant for weld joints

The structural assemblies are selectively reinforced with metal matrix composite in the regions susceptible to mechanical failure. More specifically, a channel is machined in a structural member in an area of relatively high stress. A reinforcing member is inserted into the channel. A metal powder is deposited on and around the reinforcing member. The metal powder is irradiated by a high energy source to thereby encase the reinforcing member in a metal matrix and to consolidate the metal matrix to the interior surface of the channel. The resultant assembly is lightweight and has improved strength and stiffness at room and elevated temperatures.

Selective metal matrix composite reinforcement by laser deposition

The machined-sandwich structural assembly has two components joined together with a joint of substantially the same strength as the weakest base material. More specifically, the structural assembly includes a first structural member and a second structural member. The first structural member is spaced from the second structural member through a plurality of intermediate members which extend between the first structural member and the second structural member. The plurality of intermediate members are friction stir welded to the first structural member. The resultant assembly requires less stock material, takes less time to machine and has a joint of improved strength.

Growing community of inventors

Frontenac, MO, United States of America

Rajesh Talwar