There is disclosed a sealable, flexible membrane for encapsulating a part to be isostatically pressed at an elevated temperature. The membrane includes at least one first layer of polymeric film having a melting point above the elevated temperature, and at least one second layer disposed on the first layer. The second layer comprising a metal. In one embodiment, the metal comes into contact with the part to be isostatically pressed. The membrane, which typically has a thickness ranging from 10 to about 500 μm, and is impermeable to the flow of liquids and gases when sealed, can be used to warm press parts up to about 350° C. and pressures ranging from 5,000 psi to 100.000 psi. Methods to isostatically press parts using this sealable, flexible membrane are also disclosed. Bags made from the sealable, flexible membrane that are used in isostatic presses are also disclosed.

The present invention relates to a method of manufacturing a body made of composite material such as a shell of a helmet. Said body constitutes a multilayer structure where each layer is formed by superposed strata comprising portions of fabrics preimpregnated with thermoplastic resin in which at least some of said layers are formed by woven or non-woven LFRTP-type preimpregnated fabrics. The outer layer is formed by strata of portions of “veil” type or “felt” type fabrics, with non-woven and non-oriented fibers of lengths comprised between 5 and 20 mm. In the method, the multilayer structure arranged in a mold is subjected to the action exerted by a bag that is inflated due to pressure occupying the cavity of the mold.

The present invention relates to a method of manufacturing a body made of composite material such as a shell of a helmet. Said body constitutes a multilayer structure where each layer is formed by superposed strata comprising portions of fabrics preimpregnated with thermoplastic resin in which at least some of said layers are formed by woven or non-woven LFRTP-type preimpregnated fabrics. The outer layer is formed by strata of portions of “veil” type or “felt” type fabrics, with non-woven and non-oriented fibers of lengths comprised between 5 and 20 mm. In the method, the multilayer structure arranged in a mold is subjected to the action exerted by a bag that is inflated due to pressure occupying the cavity of the mold.

A method for manufacturing a fiber-reinforced resin tube body includes: a preparing step of preparing a cylindrical expandable body having fiber wound therearound; an installing step of installing the expandable body in a mold after the preparing step; a flowing step of flowing resin into the mold, in which the expandable body is placed, after the installing step; and an expanding step of expanding the expandable body toward an inner wall of the mold after the flowing step.

Methods of forming a curvature into a composite stiffener and a forming tool are presented. The composite stiffener is positioned in a forming region created by a base assembly and an upper assembly. A first airflow is applied through the material of the base assembly. A second airflow is applied through the material of the upper assembly. A plurality of brackets of the upper assembly is moved relative to each other to change a curvature of the forming region along a length of the forming region to form the curvature into the composite stiffener.

Methods of forming a curvature into a composite stiffener and a forming tool are presented. The composite stiffener is positioned in a forming region created by a base assembly and an upper assembly. A first airflow is applied through the material of the base assembly. A second airflow is applied through the material of the upper assembly. A plurality of brackets of the upper assembly is moved relative to each other to change a curvature of the forming region along a length of the forming region to form the curvature into the composite stiffener.

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.

A forming die with a flexible blank holder is provided. The forming die includes an upper die set, a lower die set, and a blank holder with a flexible pad. The upper die set has an upper die base and an upper die insert provided on the upper die base and has a cavity surface. The lower die set has a lower die base, an elastic member on the lower die base, and a lower die punch on the lower die base. Guide posts are provided between the upper die set and the lower die set to define relative positions of the two die sets. Through relative movement of the upper and the lower die sets, a blank placed on the blank holder there between is formed by forming. During the forming, the flexible pad is tightly pressed against the blank under the pressing force of the elastic member.

A forming die with a flexible blank holder is provided. The forming die includes an upper die set, a lower die set, and a blank holder with a flexible pad. The upper die set has an upper die base and an upper die insert provided on the upper die base and has a cavity surface. The lower die set has a lower die base, an elastic member on the lower die base, and a lower die punch on the lower die base. Guide posts are provided between the upper die set and the lower die set to define relative positions of the two die sets. Through relative movement of the upper and the lower die sets, a blank placed on the blank holder there between is formed by forming. During the forming, the flexible pad is tightly pressed against the blank under the pressing force of the elastic member.

Thermal curing of a potting material within a hole in a surface of a composite material is described utilizing a flexible vacuum compression device that includes a chemical-based heating pack. The vacuum compression device includes an internal compartment within a cavity that retains the chemical-based heating pack, and a vacuum port having a passage into the cavity. An end of the vacuum compression device includes an interface that forms an air-tight seal between the cavity and the surface when applied to a surface of the composite material. Drawing a vacuum via the vacuum port collapses the vacuum compression device and positions the chemical-based heating pack proximate to the surface, enabling heat from the chemical-based heating pack to thermally cure the potting material.