Abstract A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack. An envelope gas fitting is placed between the face sheets and is welded in place while seal welding around the entire peripheral edges of the face sheet and the core pack to produce a sealed envelope pack enveloping the core pack, with gas fittings into the core pack and into a face sheet zone between the face sheets and the core pack. A gas supply tube from the gas supply control system is connected to each of the fittings and air and moisture is purged from the packs by flushing with dry argon. The packs are pressurized to a low pressure with argon to maintain separation of the sheets while heating to prevent premature diffusion bonding. The full pack is placed in an internal cavity of a heated die and is raised to superforming temperatures. Forming gas is injected through the fittings at a forming pressure sufficient to inflate the envelope pack to the interior walls of the cavity, and inflate the core pack to the envelope pack and to diffusion bond the face sheets to the core sheets. The die is opened and the formed pack is removed from the die while still at an elevated temperature.
A multisheet metal structure obtainable by the steps of: (a) assembling multiple sheets of an alloy suitable for superplastic forming in a vertical stack; (b) clamping the sheets together at a drill point and welding the sheets together around the periphery of a region in which a hole is to be drilled sequentially through the stack of sheets; (c) drilling a hole sequentially through said sheets in the region within the welded periphery so that the weld bounds the hole; (d) inserting a sleeve into the hole adjacent the weld, the sleeve having the same height as the sandwich structure at the drill point after the sheets are expanded; (e) inserting the sheets with the sleeve into a die having an internal cavity, the cavity having a shape the same as the intended design shape of the expanded sandwich structure; and (f) superplastically expanding the sheets in the die cavity to form the expanded sandwich structure and to cause the welded and drilled sheets to contact the sleeve along the length of the sleeve to define a reinforced hole, being a sealed opening, through the expanded sandwich structure.
Claim 2
Dependent Claim
188 words
A multisheet metal structure obtainable by the steps of: (a) assembling multiple sheets of an alloy suitable for superplastic forming in a vertical stack; (b) clamping the sheets together at a drill point and welding the sheets together around the periphery of a region in which a hole is to be drilled sequentially through the stack of sheets; (c) drilling a hole sequentially through said sheets in the region within the welded periphery so that the weld bounds the hole; (d) inserting a sleeve into the hole adjacent the weld, the sleeve having the same height as the sandwich structure at the drill point after the sheets are expanded; (e) inserting the sheets with the sleeve into a die having an internal cavity, the cavity having a shape the same as the intended design shape of the expanded sandwich structure; and (f) superplastically expanding the sheets in the die cavity to form the expanded sandwich structure and to cause the welded and drilled sheets to contact the sleeve along the length of the sleeve to define a reinforced hole, being a sealed opening, through the expanded sandwich structure.
Claim 3
Dependent Claim
12 words
The structure of claim 1 wherein the sleeve is a non-superplastic material.
Claim 4
Dependent Claim
14 words
The structure of claim 1 wherein the sheets contain titanium as a major constituent.