An automotive component manufacturing method includes a molding process of pressing a portion of a hollow tube formed from a metal material, or a composite material including a metal and a resin, so as to deform the portion of the hollow tube, from a tube outer side toward a tube inner side, to beyond an axial center of the hollow tube, and mold the portion of the hollow tube into a deformed section deformed with a concave profile; and a deformation process of deforming a location having a high level of residual stress in a closed cross-section configured by the deformed section so as to deform the location out-of-plane.

A manufacturing process is provided that includes arranging a tubular body with a mandrel. The tubular body circumscribes an outer surface of the mandrel and includes a panel and a sheet. The panel includes a porous first skin, a second skin and a cellular core between and connected to the porous first skin and the second skin. The sheet is configured with the second skin to form a pressure vessel. The first skin and the cellular core are located within the pressure vessel. At least a portion of the outer surface comprises an axially convex geometry. The panel is heated. The heated panel is shaped to at least partially conform to the outer surface by pressurizing fluid within the pressure vessel.

Aspects of the disclosure are directed to a bonding of a first skin and a second skin to a core material, coupling a sheet to the first skin to form with the first skin an enclosure containing the second skin and the core material, exposing the first skin, the second skin, and the core material to heat, and based on the exposition of heat, applying pressure via the enclosure to the first skin to cause the first skin to deform and expand to a shape of a die.

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.

An apparatus for forming a panel, including a first face sheet, a second face sheet and a core sheet between the first face sheet and the second face sheet, may include a molding tool defining a forming cavity shaped to correspond to the panel, a heating system positioned adjacent to the forming cavity and configured to heat the forming cavity, and a pressurization system configured to pressurize a cavity volume between the tool and the panel and pressurize a panel volume between the first face sheet and the second face sheet.

An apparatus for forming a panel, including a first face sheet, a second face sheet and a core sheet between the first face sheet and the second face sheet, may include a molding tool defining a forming cavity shaped to correspond to the panel, a heating system positioned adjacent to the forming cavity and configured to heat the forming cavity, and a pressurization system configured to pressurize a cavity volume between the tool and the panel and pressurize a panel volume between the first face sheet and the second face sheet.

Examples of forming metal composites are described herein. In an example, a metal sheet is formed into a predetermined shape using superplastic thermal forming technique. Further, a carbon fiber-reinforced polymer sheet is shaped into the predetermined shape by thermal forming. The metal sheet and the carbon fiber-reinforced polymer sheet are coupled by applying an adhesive between the metal sheet and the carbon fiber-reinforced polymer sheet, to form a metal composite.

Examples of forming metal composites are described herein. In an example, a metal sheet is formed into a predetermined shape using superplastic thermal forming technique. Further, a carbon fiber-reinforced polymer sheet is shaped into the predetermined shape by thermal forming. The metal sheet and the carbon fiber-reinforced polymer sheet are coupled by applying an adhesive between the metal sheet and the carbon fiber-reinforced polymer sheet, to form a metal composite.

A bent member is a bent member including a metallic plate that is a main body, reinforcing plates provided to extend along bent portions formed by bending the metallic plate. The reinforcing plate is fitted in the opening formed in the metallic plate, and are welded to the metallic plate.

An aerofoil structure with a hollow cavity is manufactured by diffusion bonding and superplastic forming. Outer panels are formed of a first material; a membrane is formed of a second material. Stop-off material is applied to preselected areas on at least one side of the membrane or of one of the panels so as to prevent diffusion bonding between the panels and the membrane at the preselected areas. The panels and the membrane are arranged in a stack and a diffusion bonding process is performed to bond together the first and second panels and the membrane to form an assembly. A superplastic forming process is performed at a forming temperature to expand the assembly to form the aerofoil structure. The forming temperature is selected so that the second material undergoes superplastic deformation at the forming temperature and the first material does not undergo superplastic deformation at the forming temperature.