A manufacturing method is provided during which a plurality of first apertures are formed in a first plate to provide an apertured first plate. A plurality of second apertures are formed in a second plate to provide an apertured second plate. The apertured first plate and the apertured second plate are bonded to a base sheet to form a structure. The base sheet is bent to form a bend in the structure between the apertured first plate and the apertured second plate.

Method and device for manufacturing a component from a plate made of deformable material, in particular for an edge of an element of an aircraft. The device includes a tool with two tool parts configured to be able to move closer to one another and are able to round a plate made of deformable material fixed to the two tool parts, a mold at the periphery of the tool and including a molding cavity of a shape corresponding to the shape of the component that is to be manufactured, and a displacement system configured to press the rounded plate firmly against the molding cavity of the mold, the mold being able to shape the rounded plate when it is pressed firmly against the molding cavity to give it its definitive shape, the device allowing the manufacture of single-piece components of varying sizes and notably large-sized components and/or deep components.

A method and a device for manufacturing a part starting from a cushion made of deformable material, in particular for an edge of an element of an aircraft. The device includes a preparation unit to create a cushion with two plates and, between the plates, an internal space with an opening, and a molding unit comprising a mold in which the cushion is positioned, the mold comprising two shells and an imprint corresponding to the shape of the part to be manufactured, the molding unit configured to inject a pressurized fluid into the internal space of the cushion through the opening to deform the cushion such that it matches the imprint and forms the part, the device being capable of manufacturing one-piece parts of various sizes, and in particular parts having complex shapes, in particular non-developable shapes.

A method and a device for manufacturing a part starting from a cushion made of deformable material, in particular for an edge of an element of an aircraft. The device includes a preparation unit to create a cushion with two plates and, between the plates, an internal space with an opening, and a molding unit comprising a mold in which the cushion is positioned, the mold comprising two shells and an imprint corresponding to the shape of the part to be manufactured, the molding unit configured to inject a pressurized fluid into the internal space of the cushion through the opening to deform the cushion such that it matches the imprint and forms the part, the device being capable of manufacturing one-piece parts of various sizes, and in particular parts having complex shapes, in particular non-developable shapes.

A method for producing a crossmember for a vehicle prepares a workpiece having different thicknesses and a preliminary contour from a metal sheet of uniform thickness by flat roll forming to achieve different local thicknesses. The method cuts out the workpiece, and bending roll forms the workpiece to form a crossmember with a cross section having at least two flanges opposite one another, and a web situated between said flanges. The distance between the flanges is not constant along a longitudinal extent of the crossmember, and a thickness profile at least of the web is determined by the flat roll forming. The local thicknesses and the preliminary contour are such that a geometrical shape of the crossmember corresponds to a predetermined geometrical shape with different thicknesses and heights of the web and differently shaped regions of the flanges along the longitudinal extent of the crossmember.

A die assembly for forming finished parts from blanks includes an upper die section and a lower die section. The upper die section includes an upper segmented die having a plurality of upper die segments releasably coupled to each other. The lower die section includes a lower segmented die having a plurality of lower die segments releasably coupled to each other. The die assembly is usable with a movable gantry press configured to move to a location of the die assembly and operate the die assembly.

A process for manufacturing a metal part (10), is described said part extending in a first direction (Y) and having a section comprising a central member (14) and at least a first side member (16) extending in a second direction. The process comprises the following steps: supply of a metal blank (30); removing material from the blank so as to form an intermediate part (32) comprising the central member (14), a junction zone (12) and at least first (116) and second (118) intermediate side members, with a space (34) between the first and second intermediate side members; and hot forming (104) the intermediate part, including spreading the first and second intermediate side members apart by inserting a first punch (212) between said members.

A method for forming large titanium parts includes forming bends into a titanium plate for form a bent part. The bent part is then roll-formed to form contours into the bent part. The surfaces of the contoured part are rough-machined, and the part is then secured to a bladed form fixture. The bladed form fixture comprises a plurality of header boards that secure the part to the fixture. The fixture part is placed in a thermal vacuum furnace and a stress-relieving operation is performed. The part is removed from the fixture and final machining takes place.

A method for forming large titanium parts includes forming bends into a titanium plate for form a bent part. The bent part is then roll-formed to form contours into the bent part. The surfaces of the contoured part are rough-machined, and the part is then secured to a bladed form fixture. The bladed form fixture comprises a plurality of header boards that secure the part to the fixture. The fixture part is placed in a thermal vacuum furnace and a stress-relieving operation is performed. The part is removed from the fixture and final machining takes place.

An exterior panel is formed of superplastic materials, including an exterior skin of titanium to accommodate high thermal stresses imposed on hypersonic transport vehicles during hypersonic flight. The exterior skin is fixed to an underlying reinforcing skeletal structure consisting of a superplastic formable reinforcement (SFR) layer, for example a titanium, zirconium, and molybdenum (TZM) alloy, which supports the exterior skin whenever the latter may be heated to temperatures exceeding 1200 degrees Fahrenheit. The exterior panel includes a separate interior skin configured for attachment to a frame member such as a rib, stringer, or spar of the hypersonic transport vehicle. A multicellular core is sandwiched between the exterior and interior skins to impart tensile and compressive strength to the exterior panel. In one disclosed method, the core is superplastic formed and diffusion bonded to the exterior and interior skins.