A fixture assembly includes a first fixture portion, a second fixture portion that interfaces with the first fixture portion, and a sub-fixture movably mounted to the first fixture portion. A multiple of actuators selectively move the sub-fixture toward the second fixture portion. A method of manufacturing a fan blade includes deploying the sub-fixture from the first fixture portion to effectuate a peripheral diffusion bond to join the blade body and the cover of the fan blade.

A method of forming a gas turbine engine component according to an example of the present disclosure includes, among other things, attaching a cover skin to an airfoil body, the airfoil body and the cover skin cooperating to establish pressure and suction sides of an airfoil, positioning the airfoil between first and second dies of a deforming station, heating the airfoil body to a first predefined temperature threshold between the first and second dies, and moving the first die relative to the second die to hold the airfoil between the first and second dies subsequent to the heating step, and then deforming the airfoil between the first and second dies.

Various implementations include a method of manufacturing one or more devices. The method includes obtaining a base portion of a non-shape-memory metal, disposing one or more shape-memory metal portions along the base portion, and joining at least a first layer of the non-shape-memory metal to the base portion using ultrasonic additive manufacturing. The shape-memory metal portions are disposed along a first base surface of the base portion. The shape-memory metal portions have a first portion contacting the base portion and a second portion spaced apart from the first portion and extending from the base portion. The first layer is joined to the base portion using ultrasonic additive manufacturing and has a first layer surface that is joined to the first base surface. The first layer surface contacts the shape-memory metal portions when the first layer is joined to the base portion.

A method for the manufacturing of an object. The method includes receiving a desired alloy composition for the object, depositing a plurality of foils in a stack to form the object, applying heat to the stack at a first temperature to bond the plurality of foils to each other, and applying heat to the stack at a second temperature to homogenize the composition of the stack. The homogenized stack has the desired alloy composition.

An ultrasonic welding system is provided. The ultrasonic welding system includes a support structure for supporting a workpiece. The ultrasonic welding system also includes a weld head assembly including an ultrasonic converter carrying a sonotrode. The ultrasonic welding system also includes a conductive pin supply configured to provide a plurality of conductive pins for welding using the sonotrode.

A method for the manufacturing of an object. The method includes receiving a desired alloy composition for the object, depositing a plurality of foils in a stack to form the object, applying heat to the stack at a first temperature to bond the plurality of foils to each other, and applying heat to the stack at a second temperature to homogenize the composition of the stack. The homogenized stack has the desired alloy composition.

A method of friction welding a first component to a second component, the method having the steps of: rotating the first component relative to the second component about a rotation axis; and bringing the first component into contact with the second component; wherein, while the first component and the second component are in contact, a first average force is applied during a first stage of the friction welding process and a second average force is applied during a second stage of the friction welding process; and the second average force is different from the first average force.

A method of joining a first component to a second component at respective connection surfaces, comprising, in order, applying a local surface treatment to the connection surface of at least one of the first and second components in order to locally alter the microstructure to a depth of between 60 m and 10 mm below the connection surface; and joining the first component to the second component using a welding process.

Methods are disclosed for forming metal workpieces made from a heat-treatable metal that has been shaped and tempered according to specified protocols that facilitate formation of large contoured unitary metal structures having welds that are retained in the finished structure, and finished metal structures made according to such methods.

A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.