Structure and method for forming structural components
First Claim
Patent Images
1. A method of forming a metal structure comprising the steps of:
- supporting a pair of metal sheets with a separation therebetween;
placing at least one metal tube between them metal sheets; and
superplastically expanding and deforming the at least one metal tube by injecting pressurized gas into the at least one metal tube until contact is made with the metal sheets and diffusion bonding occurs to form a support structure between the metal sheets.
5 Assignments
0 Petitions
Accused Products
Abstract
A metal structural component (10) is formed by placing metal tubes (16) between two metal sheets (12) and plastically deforming the tubes (16) by injecting pressured gas therein. The injected gas expands the tubes by superplastic deformation until diffusion bonding occurs between the metal sheets (12) and expanded tubes (16) to form the desired support structure between the metal sheets (12).
50 Citations
27 Claims
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1. A method of forming a metal structure comprising the steps of:
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supporting a pair of metal sheets with a separation therebetween; placing at least one metal tube between them metal sheets; and superplastically expanding and deforming the at least one metal tube by injecting pressurized gas into the at least one metal tube until contact is made with the metal sheets and diffusion bonding occurs to form a support structure between the metal sheets. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of forming a metal structure in a die comprising the steps of:
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lining opposed surfaces of the die with metal sheets; placing at least one metal tube between the metal sheets, and superplastically deforming the at least one metal tube by injecting non-reactive pressurized gas into the at least one metal tube until contact is made with the metal sheets and diffusion bonding occurs to form a support structure between the metal sheets. - View Dependent Claims (11, 12)
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13. A method of forming a metal structure in a two-part die having a first die portion and a second die portion, comprising the steps of:
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lining the first die portion with a first metal sheet; applying maskant to the second die portion; placing a plurality of metal tubes between the first and second die portions; superplastically expanding and deforming the metal tubes by injecting inert pressurized gas into the metal tubes until contact is made with the first metal sheet and the second die portion and diffusion bonding occurs between the first metal sheet and the thus expanded metal tubes; removing the second die portion to expose the side of the thus expanded metal tubes which is remote from the first metal sheet; and bonding a second metal sheet to the thus exposed remote side of the expanded metal tubes. - View Dependent Claims (14)
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15. A method for forming a metal structure in a die comprising the steps of:
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lining the surfaces of the die with metal sheets; placing at least one metal tube, having one sealed end and uniform wall thickness, between the metal sheets; and superplastically deforming the at least one metal tube by injecting nonreactive pressurized gas into the at least one metal tube to expand the at least one metal tube uniformly until contact is made with the metal sheets and diffusion bonding occurs, thereby forming a support structure between the metal sheets. - View Dependent Claims (16, 17)
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18. A metal structure comprising:
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an upper metal sheet and lower metal sheet; at least one expanded and superplastically deformed metal tube between the upper and lower metal sheets and diffusion bonded to the upper and lower metal sheets to form a support structure. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25)
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26. A metal structure comprising:
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at least one metal sheet; a plurality of superplastically expanded and deformed metal tubes positioned at predetermined locations along the at least one metal sheet and diffusion bonded to the at least one metal sheet to form a support structure. - View Dependent Claims (27)
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Specification