Method of manufacturing an article by diffusion bonding and superplastic forming
First Claim
1. A method of manufacturing an article of predetermined finished profile by diffusion bonding and superplastic forming at least two metal workpieces comprising the steps of:
- (a) forming a metal slab, the metal slab having first and second ends and first and second surfaces, (b) forging the first end of the metal slab to produce a region of increased thickness at the first end of the metal slab and extending from the first surface of the metal slab and forging the second end of the metal slab to produce a region of increased thickness at the second end of the metal slab and extending from the second surface of the metal slab, (c) machining the metal slab from the first surface to the second surface to form two metal workpieces, each metal workpiece has at least one surface, (d) applying a stop off material to prevent diffusion bonding to preselected areas of at least one of the surfaces of at least one of two metal workpieces, (e) assembling the at least two metal workpieces into a stack relative to each other so that the surfaces 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) heating the integral structure and internally pressurising the integral structure to cause the preselected area of at least one of the at least two metal workpieces to be hot formed to produce a hollow article of predetermined shape.
1 Assignment
0 Petitions
Accused Products
Abstract
A method of manufacturing a gas turbine engine fan blade (10) comprises forming three metal workpieces (50,52,54). A metal slab (30) is upset forged at both ends (32,34) to produce a metal block (40) with increased thickness (42,44) extending from opposite surfaces (36,38). The metal block (40) is cut in an inclined path to form two of the metal workpieces (50,52). The metal workpieces (50,52,54) are assembled into a stack (56) so that the flat surfaces (38,42,46,48) are in mating abutment. Heat and pressure is applied across the thickness of the metal workpieces (50,52,54) to diffusion bond the metal workpieces (53,52,54) together to form an integral structure (100). The integral structure (100) is hot creep formed and superplastically formed to produce the required aerofoil shape and the thickened end is machined to form the blade root (26). The method enables thinner metallic workpieces with better microstructure to be used and increases the yield of metallic workpieces.
34 Citations
25 Claims
-
1. A method of manufacturing an article of predetermined finished profile by diffusion bonding and superplastic forming at least two metal workpieces comprising the steps of:
-
(a) forming a metal slab, the metal slab having first and second ends and first and second surfaces, (b) forging the first end of the metal slab to produce a region of increased thickness at the first end of the metal slab and extending from the first surface of the metal slab and forging the second end of the metal slab to produce a region of increased thickness at the second end of the metal slab and extending from the second surface of the metal slab, (c) machining the metal slab from the first surface to the second surface to form two metal workpieces, each metal workpiece has at least one surface, (d) applying a stop off material to prevent diffusion bonding to preselected areas of at least one of the surfaces of at least one of two metal workpieces, (e) assembling the at least two metal workpieces into a stack relative to each other so that the surfaces 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) heating the integral structure and internally pressurising the integral structure to cause the preselected area of at least one of the at least two metal workpieces 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, 21, 22, 23, 24, 25)
-
Specification