A cooling apparatus for a component formed by super plastic forming including a gas source configured to supply a gas to an interior space of the component via a gas inlet, a gas outlet configured to allow the gas to exit the interior space, and a gas column connected to the gas outlet and configured to compensate for changes in an external pressure acting on the component.

A cooling apparatus for a component formed by super plastic forming including a gas source configured to supply a gas to an interior space of the component via a gas inlet, a gas outlet configured to allow the gas to exit the interior space, and a gas column connected to the gas outlet and configured to compensate for changes in an external pressure acting on the component.

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.

Within examples, a method of manufacturing a double-walled titanium conduit is described. Example methods include stitch welding multiple concentric sheets to form a stitch layer, providing the stitch layer between an inner wall and an outer wall of the double-walled titanium conduit, circumferentially seam welding the inner wall and the outer wall to the stitch layer to create a welded assembly, die forming the welded assembly at temperature and pressure to form inner structures between the multiple concentric sheets according to stitch welding lines and to enable a diffusion bond process among the inner wall, the stitch layer, and the outer wall, and removing the double-walled titanium conduit from the die.

Within examples, a method of manufacturing a double-walled titanium conduit is described. Example methods include stitch welding multiple concentric sheets to form a stitch layer, providing the stitch layer between an inner wall and an outer wall of the double-walled titanium conduit, circumferentially seam welding the inner wall and the outer wall to the stitch layer to create a welded assembly, die forming the welded assembly at temperature and pressure to form inner structures between the multiple concentric sheets according to stitch welding lines and to enable a diffusion bond process among the inner wall, the stitch layer, and the outer wall, and removing the double-walled titanium conduit from the die.

Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.

Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.

A method that includes heating a bar having an outer diameter and a length to a first temperature for a first time; extruding the heated bar to form a hollow blank having a wall thickness; forming a semi-finished blank by closing one end; bending the semi-finished blank to have an angle between first and second parts of the semi-finished blank; placing the bent semi-finished blank in a die, which is heated to a second temperature; forming a shell by injecting a gas onto or into the bent semi-finished blank after closing the die through a gas inlet in the die at a pressure for a second time, which causes the bent semi-finished blank to fit a cavity of the bathroom hardware shell shaping die; removing the shell from the die and forming a water faucet hole therein; and plating an outer surface of the shell with a coating.

A method that includes heating a bar having an outer diameter and a length to a first temperature for a first time; extruding the heated bar to form a hollow blank having a wall thickness; forming a semi-finished blank by closing one end; bending the semi-finished blank to have an angle between first and second parts of the semi-finished blank; placing the bent semi-finished blank in a die, which is heated to a second temperature; forming a shell by injecting a gas onto or into the bent semi-finished blank after closing the die through a gas inlet in the die at a pressure for a second time, which causes the bent semi-finished blank to fit a cavity of the bathroom hardware shell shaping die; removing the shell from the die and forming a water faucet hole therein; and plating an outer surface of the shell with a coating.

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.