The Boeing Company

Ravi Verma

Marc Rollo Matsen

Randall Dow Wilkerson

Lee Charles Firth

Michael Palmore Matlack

Steven Michael Shewchuk

Justin Joseph Schell

Julie Frances Murphy

Systems and methods are provided for creating precursors for consolidating composite parts. One embodiment is a method for forming a metallic structure. The method includes forming a precursor for a pressure membrane that includes a contour having a linearized length corresponding with a linearized length of a surface of a forming tool. The method also includes affixing a perimeter of the precursor to a perimeter of a base member, leaving a volume between the base member and the precursor, altering a shape of the precursor at a superplastic temperature by forcing the precursor into complementary contact with the surface of the forming tool, and setting the shape of the precursor while the precursor is held in complementary contact.

Precursor fabrication for high-temperature pressure membranes

A composite manufacturing system and method are provided. The composite manufacturing system comprises a press and a bladder. The press has an upper portion having a desired shape for a composite structure and a lower portion configured to receive layers of composite material. The bladder is associated with the upper portion of the press and is configured to reach a superplastic state when heated such that the bladder forms to the composite structure by applying heat and pressure to the layers of composite material. The bladder cools without appreciable shrinkage, applying a desired amount of pressure to the composite structure during the entire cooling cycle. Once one composite structure is formed using the bladder, the bladder may be reused to form similar structures.

Method and system for manufacturing composite structures using a magnesium bladder

A tool head assembly for a solid state additive manufacturing apparatus includes a tool head having a material passage configured to receive a material therein. The tool head is configured to deposit the material from the material passage onto a substrate of the solid state additive manufacturing apparatus to form at least one layer of the material on the substrate. The tool head includes a shoulder configured to contact the material such that rotation of the tool head frictionally stirs the material. The tool head assembly includes a barrier configured to extend along a side surface of the at least one layer as the at least one layer is deposited onto the substrate such that the barrier is configured to constrain the material from extruding past an edge of the shoulder.

Tool head assembly for solid state additive manufacturing

Described is a method of modifying material properties of a workpiece using a high-pressure-torsion apparatus, comprising a working axis, a first anvil, a second anvil, and an annular body, comprising a first total-loss convective chiller, a second total-loss convective chiller, and a heater, positioned between the first total-loss convective chiller and the second total-loss convective chiller along the working axis. The method comprises compressing the workpiece along a central axis of the workpiece and, simultaneously with compressing the workpiece along the central axis, twisting the workpiece about the central axis. The method further comprises, while compressing the workpiece along the central axis and twisting the workpiece about the central axis, translating the annular body along the working axis of the high-pressure-torsion apparatus, collinear with the central axis of the workpiece, and heating the workpiece with the heater.

Methods of modifying material properties of workpieces using high-pressure-torsion apparatuses

Described is a method of modifying material properties of a workpiece using a high-pressure-torsion apparatus, comprising a working axis, a first anvil, a second anvil, and an annular body, comprising a first recirculating convective chiller, a second recirculating convective chiller, and a heater, positioned between the first recirculating convective chiller and the second recirculating convective chiller along the working axis. The method comprises compressing the workpiece along a central axis of the workpiece and. simultaneously with compressing the workpiece along the central axis, twisting the workpiece about the central axis. The method further comprises. while compressing the workpiece along the central axis and twisting the workpiece about the central axis, translating the annular body along the working, axis of the high-pressure-torsion apparatus, collinear with the central axis of the workpiece, and heating the workpiece with the heater.

Described is a method of modifying material properties of a workpiece using a high-pressure-torsion apparatus, comprising a working axis, a first anvil, a second anvil, and an annular body, comprising a first conductive chiller, a second conductive chiller, and a heater, positioned between the first conductive chiller and the second conductive chiller along the working axis. The method comprises compressing the workpiece along a central axis of the workpiece and, simultaneously with compressing the workpiece alone the central axis, twisting the workpiece about the central axis. The method further comprises, while compressing the workpiece along the central axis and twisting the workpiece about the central axis, translating the annular body along the working axis of the high-pressure-torsion apparatus, collinear with the central axis of the workpiece, and heating the workpiece with the heater.

A method for forming a metal matrix composite (MMC) structure includes forming an assembly including at least two blocks of a primary phase material sharing an interface at which a secondary phase material is disposed. The assembly has a length, a width, and a thickness. The method also includes clamping the assembly to at least one of urge the at least two blocks toward each other or maintain the at least two blocks at a predetermined position. Also, the method includes passing a rotating friction-stir pin along the interface from the front edge to the rear edge. The friction-stir pin has a mixing length extending at least the width of the assembly, and passing the friction-stir pin along the length of the assembly disperses the secondary phase material into the primary phase material and welds the at least two blocks together.

Apparatuses and methods for fabricating metal matrix composite structures

Methods and process flows for diffusion bonding and forming metallic sheets are disclosed herein. The methods include stacking a first metallic sheet and a second metallic sheet to define a sheet stack. The methods further include creating a pneumatic seal between the first metallic sheet and the second metallic sheet to define a sealed sheet stack that defines a pneumatically isolated region. The methods also include increasing a surface area of the sealed sheet stack to define an expanded sheet stack. The methods further include compressing at least a portion of the expanded sheet stack to form a diffusion bond between a corresponding portion of the first metallic sheet and an opposed portion of the second metallic sheet thereby defining a diffusion bonded sheet stack.

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Chesterfield, MO, United States of America

Ravi Verma