A method of producing an integrated monolithic aluminum structure, the method includes the steps of: (a) providing an aluminum alloy plate with a predetermined thickness of at least 38.1 mm, wherein the aluminum alloy plate is a 7xxx-series alloy provided in an F-temper or an O-temper; (b) optionally pre-machining of the aluminum alloy plate to an intermediate machined structure; (c) high-energy hydroforming of the plate or optional intermediate machined structure against a forming surface of a rigid die having a contour in accordance with a desired curvature of the integrated monolithic aluminum structure, the high-energy hydroforming causing the plate or the intermediate machined structure to conform to the contour of the forming surface to at least one of a uniaxial curvature and a biaxial curvature; (d) solution heat-treating and cooling of the high-energy hydroformed structure; (e) machining and (f) ageing of the final integrated monolithic aluminum structure.

A method for shaping a blank comprising a metal includes a step of loading die blank onto a first die, a step of bringing the first die and a second die together, 3 step of forming a seal around the blank, and a step of injecting a pressurized molten salt into a space in die blank to supply a hydraulic pressure to the blank.

A method for shaping a blank comprising a metal includes a step of loading die blank onto a first die, a step of bringing the first die and a second die together, 3 step of forming a seal around the blank, and a step of injecting a pressurized molten salt into a space in die blank to supply a hydraulic pressure to the blank.

The present invention discloses a method for manufacturing a thin-walled metal component by three-dimensional (3D) printing and hot gas bulging. The present invention uses 3D printing to obtain a complex thin-walled preform, which reduces a deformation during subsequent hot gas bulging. The present invention avoids local bulging thinning and cracking, undercuts at the parting during die closing, and wrinkles due to the uneven distribution of cross-sectional materials, etc. The present invention obtains a high accuracy in the form and dimension through hot gas bulging. After a desired shape is obtained by hot gas bulging, a die is closed to keep the component under high temperature and high pressure for a period of time, so that a grain and a phase of the material are transformed to form a desired microstructure.

An accurate springback compensation method for sheet hydroforming component based on liquid volume control is related to a springback compensation method for curved surface part hydroformed with liquid as a punch during deep drawing process. According to the difference between a theoretical volume and a post-springback volume of a target part, an elastic deformation of the die is induced by liquid pressure, the die deformation amount is controlled to be equal to the springback amount. The accurate springback compensation control of a curved surface part is realized to overcome the problems of thickness or mechanical properties variations for different batches of sheets, and the manufacture error of the mould is considered to meet the design requirements. The liquid volume compensation is on-line and in-situ performed without mould re-machining. The advantages is good precision, simple process, high efficiency, short cycle and low cost.

The present invention discloses a method for manufacturing a thin-walled metal component by three-dimensional (3D) printing and hot gas bulging. The present invention uses 3D printing to obtain a complex thin-walled preform, which reduces a deformation during subsequent hot gas bulging. The present invention avoids local bulging thinning and cracking, undercuts at the parting during die closing, and wrinkles due to the uneven distribution of cross-sectional materials, etc. The present invention obtains a high accuracy in the form and dimension through hot gas bulging. After a desired shape is obtained by hot gas bulging, a die is closed to keep the component under high temperature and high pressure for a period of time, so that a grain and a phase of the material are transformed to form a desired microstructure.

Some embodiments of the disclosure provide methods and systems for controlling dimensions of metal hydroformed parts. According to an embodiment, a control method includes: obtaining an inner cavity volume of a target part and an inner cavity volume of a tube blank; injecting a liquid into the tube blank under a high pressure condition; determining a liquid volume compression compensation quantity according to the inner cavity volume of the target part; determining a liquid volume increment-target part corner radius relationship according to the inner cavity volume of the target part, the inner cavity volume of the tube blank, and the liquid volume compression compensation quantity; determining a liquid volume increment according to the liquid volume increment-target part corner radius relationship; and controlling dimensions of a metal hydroformed part according to the liquid volume increment.

A method of forming a material using a supersonic fluidic oscillator in a superplastic forming process and a related system. Pressurized gas, at a baseline pressure, is applied to a surface of the material when the material is received within a cavity of a forming tool. Pressure fluctuations, relative to the baseline pressure within the tool cavity, are created with a supersonic fluidic oscillator. Each pressure fluctuation (i) deforms the material and (ii) subsequently allows for a partial stress relief of the material during the forming process.

A method of forming a material using a supersonic fluidic oscillator in a superplastic forming process and a related system. Pressurized gas, at a baseline pressure, is applied to a surface of the material when the material is received within a cavity of a forming tool. Pressure fluctuations, relative to the baseline pressure within the tool cavity, are created with a supersonic fluidic oscillator. Each pressure fluctuation (i) deforms the material and (ii) subsequently allows for a partial stress relief of the material during the forming process.

An assembly for forming multiple nacelle components is disclosed. In accordance with various embodiments, the assembly includes a plurality of dies arranged about a central axis. A first one of the plurality of dies has a first wall and a first cavity extending through the first wall and a second one of the plurality of dies has a second wall and a second cavity extending through the second wall. The first wall and the second wall are configured to sandwich a pair of metal blanks there between. In various embodiments, a structural ring is configured to surround the plurality of dies.