公开(公告)号：US5591511A

公开(公告)日：1997-01-07

申请号：US323793

申请日：1994-10-17

Applicant: Ken K. Yasui

Inventor： Ken K. Yasui

IPC: B21D26/055 ,  B21D47/00 ,  B64C21/08 ,  B32B3/24

CPC classification number: B21D26/055 ,  B21D47/00 ,  Y10T29/49622 ,  Y10T29/49805 ,  Y10T29/49812 ,  Y10T428/12361 ,  Y10T428/24322 ,  Y10T428/24331

Abstract: A perforated sheet is diffusion bonded to a thin solid sheet. Each of the perforations of the perforated sheet is tapered, having a maximum diameter at the surface that is not bonded to the thin sheet and a smaller diameter at the surface that is bonded to the thin sheet. The bonded perforated sheet and thin sheet are included with other solid metallic sheets in a forming pack to be superplastically deformed into a structure. The bonded perforated sheet and thin sheet are placed on the top of the forming pack so that the thin sheet will face outwards after the structure is formed. After the superplastic deformation process is completed, the thin sheet is removed by machining to expose the perforated sheet and provide a structure for controlling laminar flow over the perforated sheet. The exposed surface of the perforated sheet includes the smaller diameter of each tapered perforation, while the inner-facing or blind surface of the sheet includes the maximum diameter. The formed structure includes internal passageways. The perforated sheet fluidly communicates the ambient atmosphere with the passageways. Control of laminar flow over the exposed surface of the perforated sheet is obtained by controlling the pressure in the passageways.

Abstract translation: 多孔板被扩散接合到薄的固体片材上。 穿孔板的每个穿孔是锥形的，具有在未粘合到薄片的表面处的最大直径，并且在结合到薄片的表面处具有较小的直径。 粘合的穿孔片材和薄片与成形包装中的其它固体金属片材一起被包含在超塑性变形结构中。 粘合的多孔板和薄板被放置在成形包装的顶部，使得薄片在形成结构后面向外。 在超塑性变形过程完成之后，通过机械加工去除薄片以暴露多孔板，并提供用于控制穿孔板上的层流的结构。 穿孔板的暴露表面包括每个锥形穿孔的较小直径，而片的内表面或盲面包括最大直径。 形成的结构包括内部通道。 穿孔板将环境大气与通道流体连通。 通过控制通道中的压力来获得穿孔板的暴露表面上的层流的控制。

公开(公告)号：US5141146A

公开(公告)日：1992-08-25

申请号：US711209

申请日：1991-06-06

Applicant: Ken K. Yasui

Inventor： Ken K. Yasui

IPC: B23K20/02 ,  F28F3/14

CPC classification number: B23K20/02 ,  B23K20/023 ,  F28F3/14 ,  Y10T29/18 ,  Y10T29/49371 ,  Y10T29/49618 ,  Y10T428/12292

Abstract: Process for fabricating a superplastically formed trusscore structure from a pair of core elements each formed of a pair of metal sheets of a superplastic material, e.g. titanium. The sheets of each core element are welded together along pairs of closely spaced weld lines, one core element having an even number and the other core element an odd number of such pairs of parallel weld lines. A slot is provided between the weld lines of each pair of weld lines. The two core elements are placed together, with the pairs of weld lines of one core element displaced laterally, preferably midway between the pairs of weld lines of the other core element. Face sheets are applied in contact with the outer sheet of each of the core elements, and the periphery of the assembly is sealed as by welding. The resulting forming pack asssembly is placed in the cavity of a forming die. The die is heated to a temperature suitable for superplastic forming, and gas pressure is applied between the sheets of each core element and in the space between each of the face sheets, forming a plurality of successive substantially similar trapezoids. Additional pressure is then applied sufficient to cause diffusion bonding of adjacent contacting non-parallel sides of the trapezoids, and of adjacent contacting top and bottom surfaces of the trapezoids and the face sheets.

Abstract translation: 用于从一对芯元件制造超塑性结构的方法，每一个芯元件由一对超塑性材料的金属板形成，例如， 钛。 每个芯元件的片材沿着成对的紧密间隔的焊接线焊接在一起，一个芯元件具有偶数，另一个芯元件是奇数个这样的平行焊接线对。 在每对焊接线的焊接线之间设置有槽。 两个芯元件放置在一起，一个芯元件的焊接线对横向移位，优选地位于另一芯元件的焊接对对之间。 将面片与每个芯元件的外片接触地施加，并且组装的周边通过焊接而被密封。 所形成的成型组件组件放置在成型模具的空腔中。 将模具加热到适于超塑性成形的温度，并且在每个芯元件的片材和每个面片之间的空间中施加气体压力，形成多个连续的基本相似的梯形。 然后施加足够的附加压力以引起梯形的相邻接触非平行侧和邻接的梯形和面板的顶部和底部表面的扩散接合。

公开(公告)号：US06305203B1

公开(公告)日：2001-10-23

申请号：US09595888

申请日：2000-06-20

Applicant: Ken K. Yasui

Inventor： Ken K. Yasui

IPC: B21D2602

CPC classification number: B21D26/055 ,  Y10S72/709 ,  Y10T29/49805

Abstract: The forming time necessary to superplastically form an object from a metal sheet is estimated by empirical analysis. The required rate of gas mass flow into a forming cavity is then determined using either a nomograph composed of four interrelated graphs, or a single graph which requires the input of fewer variables than the nomograph. The present invention may also be used to form cells of multiple sheet panels from a stack of sheets. In the latter application, forming time necessary to complete forming of the cells from an interim point where the core sheet forming pressure and the die temperature are increased from interim levels to their final values is estimated by empirical analysis. A nomograph or single graph of the present invention then determines the gas mass flow rate necessary to safely and efficiently complete forming of the cells from the foregoing interim point. In both of the foregoing embodiments, the required gas mass flow rate, which is a target value, is maintained by regulating the forming pressure until the final forming pressure is reached.

Abstract translation: 通过经验分析估计从金属板超塑性地形成物体所需的成形时间。 然后使用由四个相关图形组成的列线图或需要输入比单曲线图更少的变量的单个图来确定所需的气体质量流入成形腔的速率。 本发明还可以用于从一叠片材形成多个片材板的细胞。 在后一种应用中，通过实验分析来估计从芯片形成压力和模具温度从临时水平增加到其最终值的中间点完成细胞形成所需的时间。 然后，本发明的线图或单曲线确定从上述中间点安全且有效地完成单元的形成所需的气体质量流量。 在上述两个实施例中，作为目标值的所需气体质量流量通过调节成形压力直到达到最终成形压力来维持。

公开(公告)号：US5870304A

公开(公告)日：1999-02-09

申请号：US696553

申请日：1996-08-14

Applicant: Ken K. Yasui

Inventor： Ken K. Yasui

IPC: B21D26/055 ,  G06F19/00 ,  B21D26/02

CPC classification number: B21D26/055 ,  Y10S72/709

Abstract: A method of determining the progress of a superplastic formation process that uses controlled gas-mass flow rate of inert gas to form a part from generally one or more sheets of superplastically formable material, a process that may include selective diffusion bonding of the sheets together. The method includes using the expected initial conditions of the process to calculate a family of constant volume curves plotted on a graph of pressure versus cumulative gas-mass and then comparing the actual pressure and cumulative gas-mass that occurs during the process to determine the health of the process and to determine when the process has successfully completed. The comparison may be performed manually or automatically with a computer which has been programmed to characteristic and non-characteristic progress curve portions.

Abstract translation: 确定使用受控气体质量流量的惰性气体从一般一个或多个超塑性成形材料片形成部件的超塑性成形方法的进程的方法，该方法可以包括片材选择性扩散粘合在一起。 该方法包括使用该过程的预期初始条件来计算在压力与累积气体质量的图上绘制的恒定体积曲线族，然后比较在该过程中发生的确定健康的实际压力和累积气体质量 并确定过程何时成功完成。 可以使用已被编程到特征和非特征进行曲线部分的计算机手动或自动执行比较。

公开(公告)号：US5289965A

公开(公告)日：1994-03-01

申请号：US054227

申请日：1993-04-30

Applicant: Ken K. Yasui ,  Richard G. Pettit

Inventor： Ken K. Yasui ,  Richard G. Pettit

IPC: B23K1/008 ,  B23K31/02

CPC classification number: B23K1/008 ,  B23K31/02

Abstract: A process for forming single piece metal alloy panel structures includes both superplastic forming and braze bonding steps, and is particularly adapted to superplastically formable materials which are not particularly diffusion bondable, such as aluminum alloys. The process involves constructing a worksheet assembly from a plurality of worksheets which are associated with a brazing alloy capable of brazing the worksheets. At least two of the worksheets are joined in facing contact with each other by welding in a preselected pattern. The perimeter of the joined worksheets is then sealed, with the provision of means for permitting the admission of pressurized gas therebetween, after which the worksheet assembly is placed in a forming die. The actual structure forming process begins by heating the die and its associated worksheet assembly to a temperature suitable for superplastic forming, and simultaneously applying gas pressure at the means for admission of pressurized gas. The pressurized gas is applied to cause expansion of the sheets until the desired geometry of the structure has been attained. Following the superplastic forming step, the structure is braze bonded by ensuring that the die temperature is at or above the minimum brazing temperature of the brazing alloy for a specified period of time, thereby bonding at least some of the contacting surfaces of the structure together.

Abstract translation: 用于形成单片金属合金面板结构的方法包括超塑性成型和钎焊接合步骤，并且特别适用于不能特别扩散粘合的超塑性可成形材料，例如铝合金。 该工艺包括从能够钎焊工作表的钎焊合金相关联的多个工作表构造工作表组件。 至少两个工作表通过以预先选择的图案进行焊接而相互接合。 然后将接合的工作表的周边密封，并提供用于允许加压气体进入其间的装置，然后将工作片组件放置在成型模具中。 实际的结构形成过程开始于将模具及其相关联的工作板组件加热到适于超塑性成形的温度，同时在进入加压气体的装置处施加气体压力。 施加加压气体以引起片材的膨胀，直到达到所需结构的几何形状为止。 在超塑性成形工序之后，通过确保模具温度等于或高于钎焊合金的最小钎焊温度一定时间，将该结构钎焊接合，从而将结构的至少一部分接触面接合在一起。

公开(公告)号：US5904992A

公开(公告)日：1999-05-18

申请号：US720226

申请日：1996-09-26

Applicant: Ken K. Yasui

Inventor： Ken K. Yasui

IPC: B23K20/02 ,  B23K20/14

CPC classification number: B23K20/023 ,  B23K2201/02 ,  Y10T428/1234 ,  Y10T428/12347

Abstract: A two-sheet superplastically formed/diffusion bonded panel is made with a forming die assembly in which forming cavities are held in a flexible retaining sheet that floats in a forming box. A gas passage is provided through the box behind the cavities and the retaining sheet so that the cavities and retaining sheet are forced toward a rigid face sheet forming die element when pressurized gas is introduced. A face sheet and a reinforcing sheet sealed together around their edges, except for a gas passage to provide pressurized gas between the two sheets, are placed between the face sheet die and the forming die elements positioned in the box. The sheets are then heated and pressurized gas is applied between the sheets to cause the face sheet to move into contact with the face sheet die element while the reinforcing sheet superplastically deforms into the cavities supported by the retaining sheet to form ribs. After the ribs are formed in the reinforcing sheet, the pressure between the face and reinforcing sheets is reduced and the pressure in the box behind the cavity retaining sheet and die cavities is increased so that the formed sheet is moved against the face sheet for bonding. For dimple, as opposed to rib reinforced parts, dimples are created in a grid by shaped blocks facing the reinforcing sheet, which blocks are attached at their base to a flexible retaining sheet acted upon by pressurized gas in the gas chamber.

Abstract translation: 两片超塑性/扩散接合面板用成形模组件制成，其中成型腔保持在浮动在成型箱中的柔性保持片中。 气体通道设置在空腔后面的箱体和保持片上，使得当加压气体被引入时，空腔和保持片被迫朝向刚性的面片成形模具元件。 除了在两片之间提供加压气体的气体通道之外，围绕它们的边缘密封在一起的面片和加强片被放置在面片模具和定位在盒子中的成形模具元件之间。 然后将片材加热，并且在片材之间施加加压气体，使得面片移动成与面片模具元件接触，同时加强片材超塑性变形到由保持片材支撑的空腔中以形成肋条。 在加强板中形成肋之后，面和加强片之间的压力降低，并且腔保持片和模腔之后的盒中的压力增加，使得所形成的片材抵靠面板移动以进行粘结。 对于凹坑，与肋加强部件相反，通过面向增强板的成形块在网格中形成凹坑，该块体在其基部附接到在气体室中受加压气体作用的柔性保持片。

公开(公告)号：US5723225A

公开(公告)日：1998-03-03

申请号：US703259

申请日：1996-08-26

Applicant: Ken K. Yasui ,  David F. Bertino ,  Krishna Hoffman ,  David H. Hamilton

Inventor： Ken K. Yasui ,  David F. Bertino ,  Krishna Hoffman ,  David H. Hamilton

IPC: B32B3/12 ,  B32B15/01 ,  B32B15/00

CPC classification number: B32B15/01 ,  B32B3/12 ,  Y10T428/1234 ,  Y10T428/12347 ,  Y10T428/24182

Abstract: Four sheet SPF/DB panels having thick perpendicular webs formed between face sheets for areas of high compressive stress while other areas have relatively thinner webs so that the overall weight of the panel is not excessive. The thick webs are constructed by welding doubler strips or grids to core sheets when the core sheets are welded together into a core assembly prior to panel formation. When the core assembly so formed is superplastically deformed, the outer edges of the doubler strips bond to the face sheet and then are stretched into the centers of the thick webs, thereby thickening them for additional compressive strength. Normally such are used to reinforce edge joints between panels or supporting structure.

Abstract translation: 在具有高压缩应力的区域的面板之间形成具有厚的垂直腹板的四片SPF / DB面板，而其他区域具有相对较薄的腹板，使得面板的总重量不过大。 通过在芯板形成之前将芯片焊接在一起成为芯组件时，通过将倍频带或栅格焊接到芯片来构造厚的网。 当如此形成的芯组件被超塑性变形时，倍频带的外边缘粘合到面板上，然后被拉伸到厚幅材的中心，从而使它们增厚以获得额外的抗压强度。 通常这样用于加强面板或支撑结构之间的边缘接合。

公开(公告)号：US5692406A

公开(公告)日：1997-12-02

申请号：US721483

申请日：1996-09-27

Applicant: Ken K. Yasui

Inventor： Ken K. Yasui

IPC: B21D26/055 ,  B21D26/02

CPC classification number: B21D26/055 ,  Y10S72/709 ,  Y10T29/49805

Abstract: An improved die for a superplastic formation process and the process that uses an interface for pressurized gas that is part of the forming die so that tube welding to the forming pack can be eliminated. In one embodiment, the interface is fixed to the die and in a second, for use to pressurize the interior volume of finished parts with inert gas when the finished parts are to be removed from the die hot (1400.degree. F.), the interface becomes welded to the pack during the forming process so that the interior of the part can be flooded with inert gas during the cool down process.

Abstract translation: 用于超塑性成形工艺的改进的模具和使用作为成形模具的一部分的加压气体的界面的方法，从而可以消除对成型包装的管焊接。 在一个实施例中，界面固定在模具上，另一方面，当最终零件要从模具热（1400°F）中移除时，用于在惰性气体中加压成品零件的内部容积，界面 在成形过程中焊接到包装上，使得在冷却过程中部件的内部可以被惰性气体淹没。

公开(公告)号：US5366787A

公开(公告)日：1994-11-22

申请号：US964716

申请日：1992-10-22

Applicant: Ken K. Yasui ,  Richard G. Pettit

Inventor： Ken K. Yasui ,  Richard G. Pettit

IPC: B29C49/00 ,  B29D22/00 ,  B29D24/00 ,  B32B3/28 ,  E04C2/08 ,  B32B3/12 ,  F04C2/34

CPC classification number: B29C49/0047 ,  B29D22/00 ,  B29D24/00 ,  B32B3/28 ,  E04C2/08 ,  Y10T428/234 ,  Y10T428/24628 ,  Y10T428/24661 ,  Y10T428/24669 ,  Y10T428/24694 ,  Y10T428/24711 ,  Y10T428/24719 ,  Y10T428/24744

Abstract: The structure and process for making a metallic panel structure from a plurality, e.g. two, core elements each comprised of a pair of sheets of superplastic material welded together along a plurality of weld lines, the weld lines of one core element being spaced differently or of different shape from the weld lines of the other core element. The core elements are joined together, with the weld lines of one core panel positioned at an angle, e.g., normal, to the weld lines of the adjacent core element. The resulting panel assembly is placed in a die. The die is heated to superplastic forming temperature, and gas pressure is applied to the spaces between the sheets of the respective core elements, causing superplastic forming and expansion of the sheets of each core panel to form a first series of bulges between weld lines of one core element, and a second series of bulges dissimilar in shape, e.g. larger, than the first series of bulges, between weld lines of the adjacent core element, the bulges expanding inwardly toward each other. The two series of bulges are orthogonally disposed, the bulges from the two core elements contacting and forming around each other. Further pressurization is applied to cause diffusion bonding at the contacting areas of the two series of bulges. The resulting structure is formed of two normally disposed series of bulges, one series larger than the other, with face sheets connected to such bulges.

Abstract translation: 用于制造金属板结构的结构和工艺，从多个，例如， 两个芯元件，每个芯元件由沿着多个焊接线焊接在一起的一对超塑性材料构成，一个芯元件的焊接线与另一个芯元件的焊接线不同地或不同的形状间隔开。 芯元件连接在一起，一个芯板的焊接线与相邻的芯元件的焊接线定位成例如一般的角度。 将所得面板组件放置在模具中。 将模具加热到超塑性成形温度，并且将气体压力施加到各个芯元件的片材之间的空间，引起每个芯板的片材的超塑性成形和膨胀，从而在一个焊接线之间形成第一系列的凸起 核心元件和第二系列不同形状的凸起，例如 比第一系列的凸起更大，在相邻的芯元件的焊接线之间，凸起朝向彼此向内扩展。 这两个凸起系列是正交设置的，两个核心元件的凸起彼此接触并形成。 施加进一步的加压以在两系列凸起的接触区域处引起扩散结合。 所得到的结构由两个通常布置的一系列凸起形成，一个系列比另一个更大，其中面板连接到这种凸起。

公开(公告)号：US5850722A

公开(公告)日：1998-12-22

申请号：US721481

申请日：1996-09-27

Applicant: Ken K. Yasui

Inventor： Ken K. Yasui

IPC: B32B3/12 ,  E04C2/36 ,  E04C2/08

CPC classification number: B32B3/12 ,  E04C2/36

Abstract: A method to increase the damage resistance of a diffusion bonded panel that includes embedding reinforcing members in the panel are bonding the reinforcing members so structural redundancy occurs adjacent the bonds and the structures constructed thereby. The reinforcing members stop cracking of the panel there across by taking on the load at the end of the crack so crack growth is retarded.

Abstract translation: 增加扩散接合面板的损伤阻力的方法包括将加强构件嵌入面板中，使加强构件接合，从而在结合物和由此构成的结构附近发生结构冗余。 加强件通过在裂纹结束时承受负载而停止裂缝，从而阻止裂纹生长。