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.

A process and apparatus for forming a structure comprising: a) forming a pack from a skin sheet and a core sheet, wherein venting grooves are formed in a surface of a sheet that is adjacent to the other sheet; b) placing the pack in a mould and heating the pack; c) injecting a first gas between the core and skin sheets to urge the skin sheet against the mould; d) injecting a second gas on the side of the core sheet remote from the skin sheet to urge the core sheet against the skin sheet; e) maintaining gas pressure of the second gas thereby diffusion bonding the sheets; and f) withdrawing some or all of the first gas from the cavity.

A process and apparatus for forming a structure comprising: a) forming a pack from a skin sheet and a core sheet, wherein venting grooves are formed in a surface of a sheet that is adjacent to the other sheet; b) placing the pack in a mould and heating the pack; c) injecting a first gas between the core and skin sheets to urge the skin sheet against the mould; d) injecting a second gas on the side of the core sheet remote from the skin sheet to urge the core sheet against the skin sheet; e) maintaining gas pressure of the second gas thereby diffusion bonding the sheets; and f) withdrawing some or all of the first gas from the cavity.

A method for quick forming of a metal sheet. In an embodiment, the method includes the following steps: placing a metal sheet blank to be formed on a forming mold; introducing high-pressure gases with equal pressures simultaneously into upper and lower enclosed cavities respectively formed by the metal sheet blank and the sealing mold, and the metal sheet blank and the forming mold; heating the metal sheet blank to a preset forming temperature condition; quickly releasing the high-pressure gas from the cavity formed by the metal sheet blank and the forming mold, such that the metal sheet blank bulges; and discharging the gas from the cavity formed by the metal sheet blank and the sealing mold, and opening the mold to obtain a formed metal sheet part.

A method for quick forming of a metal sheet. In an embodiment, the method includes the following steps: placing a metal sheet blank to be formed on a forming mold; introducing high-pressure gases with equal pressures simultaneously into upper and lower enclosed cavities respectively formed by the metal sheet blank and the sealing mold, and the metal sheet blank and the forming mold; heating the metal sheet blank to a preset forming temperature condition; quickly releasing the high-pressure gas from the cavity formed by the metal sheet blank and the forming mold, such that the metal sheet blank bulges; and discharging the gas from the cavity formed by the metal sheet blank and the sealing mold, and opening the mold to obtain a formed metal sheet part.

Systems and methods are provided for creating precursors for consolidating composite parts. One embodiment is a method for forming a metallic structure. The method includes forming a precursor for a pressure membrane that includes a contour having a linearized length corresponding with a linearized length of a surface of a forming tool. The method also includes affixing a perimeter of the precursor to a perimeter of a base member, leaving a volume between the base member and the precursor, altering a shape of the precursor at a superplastic temperature by forcing the precursor into complementary contact with the surface of the forming tool, and setting the shape of the precursor while the precursor is held in complementary contact.

A process and apparatus for forming a structure comprising: a) forming a pack from a skin sheet and a core sheet, b) placing the pack in a mould and heating the pack; c) injecting a first gas between the core and skin sheets to urge the skin sheet against the mould; d) injecting a second gas on the side of the core sheet remote from the skin sheet to urge the core sheet against the skin sheet; e) maintaining gas pressure of the second gas thereby diffusion bonding the sheets; and f) injecting a third gas between the skin sheet and the mould, to force the skin sheet against the core sheet.

A process and apparatus for forming a structure comprising: a) forming a pack from a skin sheet and a core sheet, b) placing the pack in a mould and heating the pack; c) injecting a first gas between the core and skin sheets to urge the skin sheet against the mould; d) injecting a second gas on the side of the core sheet remote from the skin sheet to urge the core sheet against the skin sheet; e) maintaining gas pressure of the second gas thereby diffusion bonding the sheets; and f) injecting a third gas between the skin sheet and the mould, to force the skin sheet against the core sheet.

The present disclosure relates to an assembly for formation of a fan blade. The assembly comprises a suction panel; a pressure panel; and a membrane having a leading edge and a trailing edge. The membrane is sandwiched between the suction panel and pressure panel. The membrane comprises a gas entry slot extending in a radial direction, the gas entry slot having a radially outer receiving portion for receiving a pipe, and a radially inner portion. The radially inner portion of the gas entry slot has a substantially uniform width in a direction between the leading and trailing edge of the membrane.

A method of forming an article for finish fabrication into a fan outlet guide vane of a turbofan engine is provided. The method includes steps of: providing first and second sides of a metallic workpiece, each side having a relatively thin central region and a relatively thick peripheral region, and each side being formed from a plurality of separate pieces which are assembled in position relative to each other to provide the respective side, the pieces of each side including a plate which at least partially forms the central region, and one or more thicker blocks which at least partially form the peripheral region; stacking the first and second sides so that a contact interface is formed between the sides; diffusion bonding the first and second sides together across the interface over regions of the interface other than a preselected region thereof corresponding with the thin central regions of the first and second sides; and hot creep forming the bonded first and second sides and inflating the workpiece at the preselected region to produce the article such that the first and second sides form opposite aerofoil surfaces of the fan outlet guide vane.