Method of forming fiber and metal matrix composite

Claim 1

The method of forming contoured composite sheets containing low ductility fibers comprising, a. providing a multiplicity of composite sheets containing low ductility fibers; b. placing said multiplicity of composite sheets between a first carrier sheet and a second carrier sheet to form a package, the carrier sheets having greater overall dimensions than the composite sheets; c. restraining only the carrier sheets by means which fixedly hold their peripheries; d. pressurizing the first carrier sheet side of the package with means sufficient to cause permanent deformation and contouring of the package toward the second carrier sheet side; e. separating the carrier sheets from the composite sheets.

Claim 2

The method of forming contoured composite sheets containing low ductility fibers comprising, a. providing a multiplicity of composite sheets containing low ductility fibers; b. placing said multiplicity of composite sheets between a first carrier sheet and a second carrier sheet to form a package, the carrier sheets having greater overall dimensions than the composite sheets; c. restraining only the carrier sheets by means which fixedly hold their peripheries; d. pressurizing the first carrier sheet side of the package with means sufficient to cause permanent deformation and contouring of the package toward the second carrier sheet side; e. separating the carrier sheets from the composite sheets.

Claim 4

The method of claims 1 or 2 wherein the pressurizing means is a gas.

Claim 9

The method of fabricating a contoured structure having a low ductility fiber containing composite material core with a first skin and a second opposing skin, comprising: A. preforming the two skin portions by (1) placing together a first sheet and a second sheet of skin material within a first die with cavities, to form a sheet pair disposed laterally between opposing contoured cavities of the die, the opposing cavities having portions with the contour desired in the skin portions; (2) sealing the sheet pair around its periphery to form a pressure containing space therebetween and providing a pressurization port to said space; (3) pressurizing the space between the sheets with a fluid to permanently deform the sheets apart from each other until they contact and comply with the opposing cavities of the die; (4) releasing the sheets from fluid pressure and placement within the die; (5) cutting as a portion from the first sheet the first skin part, and as a portion from the second sheet the second skin part; the skin parts having substantially the contours desired in the skins of the structure; and B. preforming the composite core part by (1) providing a multiplicity of composite sheets containing low ductility fibers; (2) placing said multiplicity of composite material sheets between a first carrier sheet and a second carrier sheet to form a package, the carrier sheets having greater overall dimensions than the composite sheets; (3) clamping only the carrier sheets around their peripheries by means which fixedly hold the peripheries; (4) positioning a second contoured die in proximity to the second carrier sheet to receive the package upon deformation; (5) pressurizing the first carrier sheet side of the package sufficiently to cause the second carrier sheet to intimately contact the contoured die and thereby permanently deforming the carrier sheets and the composite sheets contained therebetween; (6) removing the package from the second die and separating and discarding the carrier sheets; and C. placing the preformed fiber composite core between the preformed skins to form an assembly within a third die having the contours desired in the structure being fabricated; and, D. pressing the assembly to form the structure.

Claim 10

The method of fabricating a contoured structure having a low ductility fiber containing composite material core with a first skin and a second opposing skin, comprising: A. preforming the two skin portions by (1) placing together a first sheet and a second sheet of skin material within a first die with cavities, to form a sheet pair disposed laterally between opposing contoured cavities of the die, the opposing cavities having portions with the contour desired in the skin portions; (2) sealing the sheet pair around its periphery to form a pressure containing space therebetween and providing a pressurization port to said space; (3) pressurizing the space between the sheets with a fluid to permanently deform the sheets apart from each other until they contact and comply with the opposing cavities of the die; (4) releasing the sheets from fluid pressure and placement within the die; (5) cutting as a portion from the first sheet the first skin part, and as a portion from the second sheet the second skin part; the skin parts having substantially the contours desired in the skins of the structure; and B. preforming the composite core part by (1) providing a multiplicity of composite sheets containing low ductility fibers; (2) placing said multiplicity of composite material sheets between a first carrier sheet and a second carrier sheet to form a package, the carrier sheets having greater overall dimensions than the composite sheets; (3) clamping only the carrier sheets around their peripheries by means which fixedly hold the peripheries; (4) positioning a second contoured die in proximity to the second carrier sheet to receive the package upon deformation; (5) pressurizing the first carrier sheet side of the package sufficiently to cause the second carrier sheet to intimately contact the contoured die and thereby permanently deforming the carrier sheets and the composite sheets contained therebetween; (6) removing the package from the second die and separating and discarding the carrier sheets; and C. placing the preformed fiber composite core between the preformed skins to form an assembly within a third die having the contours desired in the structure being fabricated; and, D. pressing the assembly to form the structure.