Cast unitized primary truss structure and method

• US 20050274485A1
• Filed: 06/14/2004
• Published: 12/15/2005
• Est. Priority Date: 06/14/2004
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Crook, Gordon R., Kampf, Stanley T., Post, Lee J., Nelson, Scott N., Allison, Daniel J., Wardak, Hafizullah, Camenzind, Joseph W., Heitmann, Aaron R., Huggins, George L., Meyer, Brian J.
• Granted Patent: US 7,104,306 B2
• Time in Patent Office: Days
• US Class Current: 164/349
• CPC Class Codes: B22C 9/22 Moulds for peculiarly-shaped castings
• CPC Class Codes: B64D 27/40 Arrangements for mounting power plants in aircraft
• CPC Class Codes: B64D 27/402 comprising box like supporting frames, e.g. pylons or arrangements for embracing the power plant

Abstract

A truss structure well suited for use as an engine strut on a commercial aircraft. The truss structure is cast as a single piece integrally formed component from a titanium alloy or another suitably lightweight, structurally strong material. The truss structure includes a plurality of integrally formed attachment structures which enable the truss structure to be secured to an element of an aircraft such as a wing. A plurality of attachment areas for an element such as an engine is also formed that allows the element (e.g. jet engine) to be secured to the truss structure. The truss structure includes a plurality of elongated rails and truss elements that are arranged to provide redundant load paths to ensure that a failure of any one truss element or elongated rail will not result in a failure of the overall truss structure to support whatever load is required.

Claims

1. A method of creating a truss-like primary support structure as an integrally formed, single piece component, the method comprising:

providing a mold for receiving a quantity of flowable titanium, the mold being adapted to form a truss-like structure having a plurality of independent, interconnected truss elements and a plurality of nodes where said truss elements intersect, at least one portion enabling the truss-like structure to be secured to a portion of an independent structure;

heating a quantity of titanium to a temperature to produce a flowable titanium;

filling the mold with said flowable titanium;

allowing the mold to cool; and

removing the truss-like structure from the mold.

2. The method of claim 1, further comprising forming the truss elements with a circular shaped cross section.

3. The method of claim 1, further comprising forming the truss elements with a rounded, quadrilateral shaped cross section.

4. The method of claim 1, wherein the truss elements are arranged, analyzed and sized with a plurality of spaced apart interconnecting nodes so that a structural integrity of the truss-like structure is not destroyed in the event of a failure of any one of said truss elements.

5. The method of claim 1, wherein the mold is used to form a truss-like structure comprising a strut for securing a jet engine to a wing of an aircraft.

6. A method of creating a truss structure as an integrally formed, single piece component for use as a load supporting component for a mobile platform, the method comprising:

providing a mold for receiving a quantity of flowable titanium, the mold being adapted to form a truss structure having a plurality of independent, interconnected truss elements and a plurality of nodes where said truss elements intersect, at least one portion enabling the truss-like structure to be secured to a portion of a mobile platform;

heating a quantity of titanium to a temperature to produce a flowable titanium;

filling the mold with said flowable titanium;

allowing the mold to cool; and

removing the truss structure from the mold.

7. The method of claim 6, further comprising forming the truss elements with a circular shaped cross section.

8. The method of claim 6, further comprising forming the truss elements with a rounded quadrilateral shaped cross section.

9. The method of claim 6, further comprising forming portions of said of said truss structure with a first thickness and portions of said truss structure with a second thickness greater than said first thickness, said portions of said second thickness representing areas where said truss structure can be machined to form precisely located structural elements for attaching said truss structure to said mobile platform.

10. The method of claim 6, further comprising performing a machining operation to machine said portions of said second thickness to form attachment nodes where said truss structure may be attached to said mobile platform.

11. The method of claim 6, further comprising performing a machining operation to machine said portions of said second thickness to form attachment nodes where said truss structure may be attached to an independent component.

12. The method of claim 6, wherein forming the truss structure comprises forming at least one portion thereof suitable for enabling the truss structure to be secured to an aircraft engine.

13. A method for forming a primary aircraft structure suitable for use in constructing a commercial passenger aircraft, the method comprising:

forming a monolithic truss through a casting process as a single piece component, the truss being formed from a titanium alloy;

further forming the truss with a plurality of truss elements, the truss elements intersecting at a plurality of nodes, the nodes and truss elements being arranged in a manner that enables a structural integrity of the truss to be maintained in the event of a failure of one of the truss elements; and

further forming the truss with at least one attachment point suitable for securing the truss to a portion of an aircraft structure.

14. The method of claim 13, further comprising forming the monolithic truss with at least one attachment point for securing to an engine of said aircraft.

15. The method of claim 13, further comprising forming the monolithic truss with dimensions and strength suitable for supporting a jet engine from a wing of said aircraft.

16. The method of claim 13, further comprising forming the truss elements with a rounded quadrilateral shaped cross section.

17. The method of claim 13, further comprising forming the truss elements with a circular shaped cross section.

18. The method of claim 13, further comprising forming the truss from a titanium alloy Ti-6AL-4V.

19. A monolithic, integrally formed truss for supporting a load from a structure, comprising:

a plurality of elongated rails;

a plurality of interconnected truss elements secured to selected ones of said elongated rails, said truss elements formed through a casting process from titanium to produce an integral, single-piece component, said truss elements being interconnected with said elongated rails, and with one another, at a plurality of nodes;

at least one first attachment element for securing said truss to said structure; and

at least one second attachment element for securing said load to said structure.

20. A monolithic, integrally formed engine strut for supporting a jet engine from a wing of a mobile platform, comprising:

a plurality of elongated rails;

a plurality of truss elements secured to selected ones of said rails at a plurality of connection nodes;

a plurality of integrally formed wing attachment structures for securing said engine strut to said wing;

a plurality of integrally formed engine mount attachment structures for securing said jet engine to said truss; and

wherein said engine strut is cast as a single piece component from titanium.