Method of manufacturing an article by superplastic forming and diffusion bonding
First Claim
1. A method of manufacturing an article having an outer profile by superplastic forming and diffusion bonding at least two metal workpieces comprising the steps of:
- (a) forming a first metal workpiece which has a first flat surface and a second flat surface, (b) forming a second metal workpiece which has a first flat surface, the second metal workpiece being thicker than the first metal workpiece, the first and second metal workpieces defining the outer profile of the article, (c) machining the second metal workpiece on a second surface opposite to the first flat surface to give a predetermined mass distribution in the second metal workpiece, (d) applying a stop off material to prevent diffusion bonding to preselected areas of at least one of the flat surfaces of at least one of the at least two workpieces, (e) assembling the at least two metal workpieces into a stack relative to each other so that the first flat surfaces of the first and second metal workpieces are in mating abutment, (f) applying heat and pressure across the thickness of the at least two metal workpieces to diffusion bond the at least two metal workpieces together in areas other than the preselected areas to form an integral structure, (g) placing the integral structure in a hot creep forming die, the die having a convex surface, the integral structure being placed in the die such that the second flat surface of the first metal workpiece faces the convex surface of the die, heating the integral structure while it is within the die to cause the integral structure to be hot creep formed on the convex surface of the die, (h) placing the integral structure in a superplastic forming dies heating the integral structure and internally pressurising the integral structure while it is within the die to cause the preselected area of at least the second metal workpiece to be hot formed to produce a hollow article of predetermined shape.
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Accused Products
Abstract
A method of manufacturing an article (10) from two metal workpieces (30,32), the first and second metal workpieces (30,32) define the outer profile of the article (10). The second workpiece (32) is thicker than the first workpiece (30). The first workpiece (30) has two flat surfaces (34,36) and the second workpiece has one flat surface (38) and one machined (42) surface (40). Stop of is applied to surface (34) to prevent diffusion bonding at preselected areas. The workpieces (30,32) are assembled into a stack (58) so that the flat surfaces (34,38) are in abutment. Heat and pressure are applied to diffusion bond the workpieces (30,32) together to form an integral structure (60). The integral structure (60) is placed in a die such that the first workpiece (30) faces a convex surface of the die. The integral structure (60) is heated to cause the integral structure (60) to be hot creep formed on the convex surface of the die. The integral structure (62) is hot formed in a superplastic forming die by heating and internally pressurising the integral structure (62) to cause a preselected area of the second workpiece to be hot formed to produce the article (10).
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Citations
20 Claims
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1. A method of manufacturing an article having an outer profile by superplastic forming and diffusion bonding at least two metal workpieces comprising the steps of:
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(a) forming a first metal workpiece which has a first flat surface and a second flat surface, (b) forming a second metal workpiece which has a first flat surface, the second metal workpiece being thicker than the first metal workpiece, the first and second metal workpieces defining the outer profile of the article, (c) machining the second metal workpiece on a second surface opposite to the first flat surface to give a predetermined mass distribution in the second metal workpiece, (d) applying a stop off material to prevent diffusion bonding to preselected areas of at least one of the flat surfaces of at least one of the at least two workpieces, (e) assembling the at least two metal workpieces into a stack relative to each other so that the first flat surfaces of the first and second metal workpieces are in mating abutment, (f) applying heat and pressure across the thickness of the at least two metal workpieces to diffusion bond the at least two metal workpieces together in areas other than the preselected areas to form an integral structure, (g) placing the integral structure in a hot creep forming die, the die having a convex surface, the integral structure being placed in the die such that the second flat surface of the first metal workpiece faces the convex surface of the die, heating the integral structure while it is within the die to cause the integral structure to be hot creep formed on the convex surface of the die, (h) placing the integral structure in a superplastic forming dies heating the integral structure and internally pressurising the integral structure while it is within the die to cause the preselected area of at least the second metal workpiece to be hot formed to produce a hollow article of predetermined shape. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification