Method and apparatus for remedying nonconforming features of aluminum alloy parts

Abstract

The invention is entitled Method and apparatus for remedying out-of-tolerance features of aluminum alloy parts. The disclosure relates to remedying out-of-tolerance features of aluminum alloy parts. A method can include identifying a yield strength of a specified aluminum alloy part as a function of temperature, determining a stress to be applied to a feature to recondition an out-of-tolerance feature within a dimensional tolerance, correlating the stress with the identified yield strength to determine a processing temperature of the part after the stress is applied to the feature, determining a time period to apply the stress to the feature at the determined processing temperature, and applying the stress to the feature of the part, the feature being constrained against the stress while the feature is heated to the determined processing temperature, and maintaining the stress and heat to the feature for the time period to recondition the constrained feature within the dimensional tolerance.

Description

Technical Field

[0001] This disclosure generally relates to aluminum alloy parts. More specifically, this disclosure relates to methods and apparatus for remedying nonconforming features in aluminum alloy parts. Background Technology

[0002] It is known that malleable aluminum alloy parts retain residual material stress after machining. This residual material stress can cause bending, twisting, and flexing of one or more features of the final part, resulting in dimensional non-compliance of those features. In applications requiring strict adherence to dimensional tolerances (one or more) (e.g., aircraft manufacturing), non-compliance of aluminum alloy features (one or more) is often problematic.

[0003] Typical remedies for non-conforming features on aluminum alloy parts include, for example, adding shims to fill gaps, applying weight to reshape the non-conforming features within dimensional tolerances, and so on. In some extreme cases, the aluminum alloy parts are practically scrapped, which affects delivery schedules and often adds significant time and cost to remanufacturing the parts. Alternatively, the features of the aluminum alloy parts will undergo additional heat treatment to heat them to the processing temperature and then reshape them while still at the processing temperature. However, reshaping aluminum alloy parts at the processing temperature often results in a degradation of the material properties of the aluminum alloy parts (i.e., reduced mechanical properties), making it necessary to scrap the reshaped aluminum alloy parts in some cases.

[0004] Therefore, it is necessary to remedy the non-conforming characteristics of aluminum alloy parts without sacrificing mechanical properties, while still meeting the requirements of specified dimensional tolerances. Summary of the Invention

[0005] This disclosure relates to methods and apparatus for remedying nonconforming features of aluminum alloy parts. One example of this disclosure relates to a method comprising: identifying a yield strength of a specified aluminum alloy part as a function of temperature; determining a stress to be applied to a nonconforming feature of the aluminum alloy part to reshape the nonconforming feature within a dimensional tolerance; correlating the stress with the identified yield strength to determine a processing temperature of the aluminum alloy part after the stress is applied to the feature; determining a time period for applying the stress to the feature at the determined processing temperature, the time period being a function of at least the stress and the determined processing temperature; and applying the stress to a feature of the aluminum alloy part, the feature being constrained to resist the stress, while heating the feature to the determined processing temperature, and maintaining the applied stress and heating to the feature for the time period to reshape the constrained feature within the dimensional tolerance.

[0006] In another instance, this disclosure also provides an apparatus comprising: a first portion arranged to constrain a non-conforming feature of an aluminum alloy part against stress applied to the feature; and a second portion arranged to apply stress to the constrained feature; wherein the constrained feature is heated to a processing temperature corresponding to the identified yield strength of a specified aluminum alloy part, and stress is applied to the constrained feature for a period of time, the period of time being a function of stress and processing temperature, in order to reshape the constrained feature within dimensional tolerances.

[0007] These and other features, aspects, and advantages of this disclosure will become apparent from the following detailed description and the accompanying drawings, which are briefly described below. This disclosure includes any combination of two, three, four, or more features or elements set forth in this disclosure or recited in any one or more claims, regardless of whether such features or elements are expressly combined or otherwise recited in the detailed description or claims herein. Unless the context of this disclosure explicitly indicates otherwise, this disclosure is intended to be read in its entirety as such that any individual feature or element of this disclosure should be considered as intended to be composable in any aspect and implementation. Attached Figure Description

[0008] Therefore, examples of this disclosure have already been described in general terms, and reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0009] Figure 1 The diagram illustrates a device used to remedy defects in aluminum alloy parts; and

[0010] Figure 2 This diagram illustrates a method for remedying defects in aluminum alloy parts. Detailed Implementation

[0011] Some examples of this disclosure will now be described more fully below with reference to the accompanying drawings, which show some, but not all, examples of this disclosure. In fact, various examples of this disclosure may be embodied in many different forms and should not be construed as limited to the examples set forth herein; rather, these examples are provided so that this disclosure will be thorough and complete and will fully convey the scope of this disclosure to those skilled in the art. For example, unless otherwise indicated, referring to something as first, second, etc., should not be construed as implying a particular order. Similarly, something described as above something (unless otherwise stated) may be below, and vice versa; and similarly, something described as to the left of something may be to the right of something, and vice versa. Throughout the drawings, the same reference numerals refer to the same elements.

[0012] Examples of this disclosure generally relate to methods and apparatus for remediating nonconforming features in aluminum alloy parts. As disclosed herein, these methods and apparatuses are used in aerospace applications to remedy nonconforming features in aluminum alloys (e.g., stiffeners, parallel surfaces, etc.). However, the methods and apparatuses disclosed herein can also be used in any application where one or more features of a forgeable or forged aluminum alloy part need to be reworked within desired dimensional tolerances. As used herein, “dimensional tolerance(s)” refers to the amount by which a given dimension or geometric property of a feature is allowed to vary without affecting the mechanical properties of the aluminum alloy part. Dimensional tolerances are selected based on the intended use of the part, where parts used in aerospace applications require strict dimensional consistency and therefore have narrow dimensional tolerances. Typically, dimensional tolerances are established during the part design phase to determine the “dimensional tolerance” used herein before implementing the disclosed methods.

[0013] Aluminum alloy parts are typically formed using conventional forming methods (e.g., rolling, forging, machining, etc.). However, in some cases, one or more features of the formed aluminum alloy part do not meet the desired dimensional tolerances. This is, for example, due to residual stresses retained during the forming or machining of the aluminum alloy part. These stresses often cause the aluminum alloy part to bend, twist, and / or buckle, resulting in dimensional nonconformities or failure to comply with specified dimensional tolerances. Dimensional nonconformities also frequently occur in previously compliant parts due to minor variations in manufacturing or machining methods. Therefore, the methods and apparatus disclosed herein remedy nonconforming features (one or more) of aluminum alloy parts by heating the nonconforming features (one or more), in some cases constrained to a processing temperature corresponding to the identified yield strength of the specified aluminum alloy part, and applying stress to the constrained features for a period of time, which is at least a function of stress and processing temperature, in order to restore the constrained features to within dimensional tolerances.

[0014] In some instances, thermally activated elastic straightening, or "pseudo-creep," mechanisms are used to elastically deform non-conforming features of aluminum alloy parts to conform to desired dimensional tolerances. The thermally activated elastic straightening mechanism is activated when the non-conforming feature of the aluminum alloy part is subjected to heat and stress (stress below the yield strength of the aluminum alloy). Once activated, the thermally activated elastic straightening mechanism allows the non-conforming feature to be moved a recalibrated distance within the desired dimensional tolerance without sacrificing mechanical properties.

[0015] For example, and as Figure 1The diagram illustrates a device 100 for remedying a non-conforming feature 102 in an aluminum alloy part 104. In a specific aspect, the aluminum alloy part 104 includes parts, components, modules, products, and / or any other element formed of malleable or forged aluminum alloys. For example, the aluminum alloy part 104 may be designated as: malleable aluminum alloy series 2000 under T6XX, T72, or T8XX conditions; malleable aluminum alloy series 6000 under T6XX conditions; or malleable aluminum alloy series 7000 under T6XX, T76XX, T73XX, and T74XX conditions.

[0016] In one aspect, the device 100 includes a first portion 106 arranged to constrain a non-conforming feature 102 of an aluminum alloy part 104 against stress applied to the feature 102. For example, the first portion 106 includes a vise, clamp, pressure plate, etc., arranged relative to the aluminum alloy part 104 to constrain the non-conforming feature 102 and resist stress applied to the feature 102. In this example, the first portion 106 is capable of constraining the non-conforming feature 102 of the part 104 having a thickness between about 40 per thousand and about 150 inches. However, other part thicknesses are also contemplated in this disclosure.

[0017] In some respects, the first part 106 is fitted to the aluminum alloy part 104 to restrain the non-conforming feature 102 from stresses applied thereto. For example, and as... Figure 1 As illustrated, the first portion 106 has a cross-sectional shape, such as an inverted "L" shape, which complements the cross-sectional shape of the aluminum alloy part 104, such as an inverted "T" shape, such that the horizontal portion of the "T" shape is constrained to resist stresses applied to the defective feature 102 (e.g., the vertical portion of the inverted "T" shape is not perpendicular to the horizontal portion of the "T" shape). The first portion 106 is configured such that when the defective feature 102 is rearranged to be perpendicular to the horizontal portion of the "T" shape, the end of the first portion 106 will be in direct contact with the defective feature 102 to resist stresses applied to the feature 102.

[0018] In some other respects, the first part 106 is arranged to adapt to one or more aluminum alloy parts with different shapes, sizes and cross sections, or is arranged to receive the aluminum alloy part 104 and “over-form” or form the feature 102 into a shape different from the desired shape, such that the natural relaxation of the aluminum results in the realization of the desired shape (e.g., conforming to dimensional tolerances).

[0019] In some aspects, the device 100 also includes a second portion 108 arranged to apply stress to the constrained feature 102. For example, the second portion 108 is arranged to apply stress sufficient to restore the non-conforming feature 102 within dimensional tolerances. This stress (σ) is determined by calculating the force (F) applied per unit area (A) (Equation 1):

[0020] Equation 1: σ = F / A,

[0021] Where F is in Newtons, A is in square meters, and σ is in N per square meter or Pascal (Pa).

[0022] However, before determining the stress, feature 102 of the aluminum alloy part 104 is measured to determine whether it is within dimensional tolerances. In a specific aspect, the methods and apparatus disclosed herein are capable of reshaping (or moving) non-conforming features by a reshaping distance of approximately 0.5 to 500 inches to the desired dimensional tolerances. However, other distances greater than or less than 0.5 to 500 inches are also contemplated within this disclosure.

[0023] If the measurement of a feature (e.g., feature 102) does indeed conform to the desired dimensional tolerance, further processing of the part continues, and the disclosed method is not required and therefore not performed. However, if the measurement of a feature does not conform to the desired dimensional tolerance, the yield strength (or more than one yield strength) is identified or selected as a function of the temperature of the specified aluminum alloy part 104. Yield strength represents the elastic limit of an aluminum alloy part, or the maximum extent to which a nonconforming feature can be stretched without permanently changing its size or shape. Because different aluminum alloy parts have different shapes and therefore different elastic limits, the identified yield strengths (one or more) will vary at least depending on the shape of the part, the specified aluminum alloy part (e.g., T6XX), the part thickness, and the corresponding temperature. In some aspects, known material databases, such as ASM International's ALLOY CENTER DATABASE, were accessed. TM This is to identify the yield strength associated with the specified aluminum alloy parts and to determine the appropriate processing temperature and time period.

[0024] For example, known material databases include the 2000 series of malleable aluminum alloys under T6XX, T72, or T8XX conditions (between 200°F and 400°F, at 10-50 kpsi for 1 / 2 to 32 hours, with parts up to seven (7) inches thick); the 6000 series of malleable aluminum alloys under T6XX conditions (between 200°F and 400°F, at 10-38 kpsi for 3 / 4 to 32 hours, with parts up to eight (8) inches thick); and the 7000 series of malleable aluminum alloys under T6XX, T76XX, T73XX, and T74XX conditions (between 200°F and 375°F, at 10-65 kpsi for 1 / 2 to 32 hours, with parts up to ten (10) inches thick). For comparative purposes, in some instances, two different yield strengths are identified for a specified aluminum alloy part at “low temperature” and “high temperature” (e.g., 200°F and 375 / 400°F), where the corresponding yield strength varies with temperature. Additional yield strengths of the aluminum alloy name (e.g., three, four, five, six, etc.) are also identified as a function of temperature if desired.

[0025] Once the yield strength is determined, the calculated stress (i.e., by Equation 1) is correlated with the determined yield strength to determine the processing temperature of the aluminum alloy part 104. The correlation of stress with the determined yield strength to determine the processing temperature depends on the number of yield strengths determined (i.e., one yield strength, two yield strengths, three yield strengths, etc.), including correlating stress with one yield strength, two yield strengths, three yield strengths, four yield strengths, etc. More specifically, the calculated stress is compared with one or more determined yield strengths to determine if the calculated stress is less than one or more yield strengths. If the calculated stress is less than at least one of the determined yield strengths, the calculated stress can be used to rework the non-conforming feature 102. This is due to a thermally activated elastic straightening mechanism. In this way, and based on the available aluminum alloy names, the calculated stress is typically between approximately 10 klb / s² and approximately 65 klb / s².

[0026] Based on the correlation between stress and the determined yield strength, two yield strengths, three yield strengths, etc., the processing temperature (the temperature at which the part is heated to reorganize the non-compliance characteristics in conjunction with the applied stress) can then be determined as the temperature corresponding to the identified yield strength. In one specific aspect, if the stress is less than each of two or more identified yield strengths, the processing temperature is the temperature corresponding to the lower of the two identified yield strengths. In another specific aspect, if the stress is greater than one of the identified yield strengths but less than the other, the processing temperature is the temperature corresponding to the higher of the two identified yield strengths. For example, the stress calculated in Formula 1 is correlated or compared with the yield strength at each selected temperature, such as "low temperature" (e.g., 200°F) and "high temperature" (e.g., 375 / 400°F), and it is determined to be lower than both the low and high temperatures. Therefore, in this example, the processing temperature is determined as the temperature corresponding to the lower of the two identified yield strengths or the "low temperature," such as 200°F. In this way, and based on the available aluminum alloy names, the processing temperature is typically between about 200°F and about 400°F.

[0027] Once the processing temperature is determined, the time period during which stress is applied to feature 102 at that temperature is also determined. This time period is at least a function of the stress and the determined processing temperature. However, in some aspects, other variables influence the time period, such as, for example, resetting distance, part thickness, etc. In some specific aspects, the time period corresponds to the time between the specified yield strength and the processing temperature for the identification of a given aluminum alloy part 104. For example, the time period for the non-conforming feature 102 of part 104 designated as T72, a malleable aluminum alloy series 2000, is 0.5 hours to 32 hours, during which the constrained feature 102 is monitored at regular intervals to determine whether the constrained feature 102 has moved the resetting distance.

[0028] Other aspects of determining the time period include, for example, determining the time period based on the renormalization distance, bending moment, calculated stress, and material properties of part 104. In this way, and based on the available aluminum alloy names, the time period is typically between approximately 0.5 hours and approximately 32 hours.

[0029] Once the stress, processing temperature, and time period are determined, preparations can be made to remediate nonconforming features. It is worth noting that physical constraints, such as processing temperature or stress uniformity, sometimes require adjustments to one or more of these factors to allow for effective, low-cost remediation of nonconforming features. For example, large equipment is needed to remediate nonconforming features on large aluminum alloy parts such as ribs or spars. In this instance, it is sometimes advantageous to apply "low" stress to the nonconforming feature of the large aluminum alloy part at a "high" processing temperature for a "short" time period, thereby reducing the investment cost of the equipment. In another instance, using large equipment to remediate nonconforming features with complex shapes, it is sometimes advantageous to apply "high" stress at a "low" processing temperature for a "long" time period to maintain uniform processing temperature across the entire aluminum alloy part. This requires less energy input to the equipment to maintain the processing temperature and allows for shorter processing cycle times (i.e., less time is needed to heat and cool the large equipment at temperatures lower than the higher processing temperatures). Alternatively, depending on the physical constraints of the apparatus used to remedy the nonconforming feature, it is advantageous to apply "high stress" for a "short" time period at a "low" processing temperature, "low stress" for a "long" time period at a "low" processing temperature, or "low stress" for a "short" time period at a "low" temperature.

[0030] In some aspects, such as Figure 1 As illustrated, the apparatus 100 further includes a heating element 110 arranged to heat the constrained feature 102 to a processing temperature. In some aspects, for example, the apparatus 100 is a furnace, or other apparatus capable of heating the part 104 to a processing temperature and maintaining it at the processing temperature for a defined duration. In some instances, the heating element 110 is an ignition mechanism that ignites a fuel source to produce a flame, a resistance heating element, etc. Furthermore, in some aspects, the heating element 110 can be controlled by a control device 112 to generate sufficient heat to heat the non-conforming feature 102 to the processing temperature and maintain it for a specified duration. In some aspects, the control device 112 is a mechanical switch, bellows, non-transitory computer-readable medium, any combination thereof, etc., capable of communicating with and controlling at least the heating element 110.

[0031] Therefore, in some aspects, the non-conforming feature 102 is confined within a first portion 106 of the device 100, and stress is applied to the confined feature 102 using a second portion 108 of the device 100. The feature 102 is then heated to a predetermined processing temperature using a heating element 110 operably engaged therewith. Optionally, the feature 102 is monitored at time intervals over a period of time to determine whether the feature 102 has moved a resetting distance. Once the feature 102 has moved a resetting distance and / or after a predetermined period of time, the application of heat from the heating element 110 and the application of stress from the second portion 108 of the device 100 are stopped to reduce the temperature of the confined feature 102 below the predetermined processing temperature. In some aspects, a control device 112 is used to initiate, stop, and monitor the resetting of the non-conforming feature 102.

[0032] After the temperature of the constrained feature 102 is lowered below a predetermined processing temperature, feature 102 is removed from the first section 106 and measured to determine whether the reshaped feature 102 is within dimensional tolerances. It is worth noting that once the constrained feature 102 is heated to the processing temperature, the aluminum alloy part can be removed from the apparatus 100. However, it is advantageous to keep feature 102 constrained until its temperature is below the processing temperature, as this reduces deformation caused by cooling while feature 102 is constrained. If feature 102 has not yet moved the reshaped distance, feature 102 is constrained again, and the heating process is repeated until a predetermined time period at the predetermined processing temperature is reached.

[0033] Optionally, if feature 102 is heated and constrained only for a portion of a defined time period, feature 102 is constrained again and the heating process is repeated for the remainder of that time period at a second processing temperature. For example, if a 6061-T6XX aluminum alloy part is operated for a period of 5 hours at a first processing temperature of 300°F, then the 6061-T6XX aluminum alloy part can only be operated for a period of 16 hours at a second processing temperature of 275°F, or for a period of 1.5 hours at a second processing temperature of 350°F. In this way, the method described herein is repeated to determine a second processing temperature that differs from the initially or previously determined processing temperature.

[0034] If feature 102 has been moved by a rework distance, part 104 is dimensionally tolerable and can be utilized as needed. In this way, the first portion 106 and the second portion 108 of device 100 are operatively engaged to move the non-conforming feature 102 by a rework distance (i.e., rework the non-conforming feature 102 by approximately 0.5 to 500 inches) within the dimensional tolerance without affecting the mechanical properties of the aluminum alloy part 104.

[0035] For reference Figure 2The diagram illustrates a method 200 for remedying non-conforming features of an aluminum alloy part. Method 200 includes, in a first step 202, determining the yield strength of a specified aluminum alloy part as a function of temperature. The method further includes, in a second step 204, determining a stress to be applied to the feature to reshape the non-conforming feature within dimensional tolerances. The method further includes, in a third step 206, correlating the stress with the determined yield strength to determine a processing temperature of the aluminum alloy part after the stress is applied to the feature. The method further includes, in a fourth step 208, determining a time period for applying stress to the feature at the determined processing temperature, the time period being a function of at least the stress and the determined processing temperature. The method further includes, in a fifth step 210, applying stress to a feature of the aluminum alloy part, constraining it against the stress, while heating the feature to the determined processing temperature, and maintaining the applied stress and heat to the feature for the duration of the time period to reshape the constrained feature within the dimensional tolerances.

[0036] Clause 1: A method comprising: identifying the yield strength of a specified aluminum alloy part as a function of temperature; determining stress to be applied to a nonconforming feature of the aluminum alloy part to reform the nonconforming feature into dimensional tolerances; correlating the stress with the identified yield strength to determine a processing temperature of the aluminum alloy part after stress is applied to the feature; determining a time period for applying stress to the feature at the determined processing temperature, the time period being a function of at least the stress and the determined processing temperature; applying stress to a feature of the aluminum alloy part, the feature being constrained to resist the stress, while heating the feature to the determined processing temperature; and maintaining the application of stress and heat to the feature for the duration of the time period to reform the constrained feature into the dimensional tolerances.

[0037] Clause 2: The method described in Clause 1, wherein determining stress includes calculating stress based on the force to be applied to a feature per unit area.

[0038] Clause 3: The method described in Clause 1 or 2, wherein determining the yield strength includes determining two or more yield strengths as a function of temperature.

[0039] Clause 4: The method of Clause 3, wherein associating stress with an identified yield strength comprises associating stress with two or more identified yield strengths to determine the processing temperature of the aluminum alloy part after stress is applied to the feature, and wherein if the stress is less than each of the two or more identified yield strengths, the processing temperature is the temperature corresponding to the lower of the two identified yield strengths, and if the stress is greater than one of the identified yield strengths but less than the other of the identified yield strengths, the processing temperature is the temperature corresponding to the higher of the two identified yield strengths.

[0040] Clause 5: The method described in any one of Clauses 1-4, wherein determining the yield strength comprises determining the yield strength of the aluminum alloy part as a function of temperature, the aluminum alloy part being named in at least one of the following: a malleable aluminum alloy series 2000 under T6XX, T72 or T8XX conditions; a malleable aluminum alloy series 6000 under T6XX conditions; and a malleable aluminum alloy series 7000 under T6XX, T76XX, T73XX and T74XX conditions.

[0041] Clause 6: The method described in any one of Clauses 1-5, wherein correlating stress with the identified yield strength to determine the processing temperature includes correlating stress with the identified yield strength to determine a processing temperature between about 200°F and about 400°F.

[0042] Clause 7: The method described in any one of Clauses 1-6, wherein determining the stress includes determining the stress to be applied to the feature in order to reshape the non-conforming feature within the dimensional tolerance in an amount of about 5 to 500 inches.

[0043] Clause 8: The method described in any one of Clauses 1-7, wherein determining the time period includes determining a time period between about 0.5 hours and about 32 hours.

[0044] Clause 9: The method described in any one of Clauses 1-8, wherein determining stress includes determining stress between about 10,000 pounds per square inch and about 65,000 pounds per square inch.

[0045] Clause 10: The method described in any one of Clauses 1-9 further includes constraining the nonconforming feature in a first part of the device and applying stress to the constrained feature using a second part of the device.

[0046] Clause 11: The method described in Clause 10 further includes heating the feature to a determined processing temperature using a heating element operatively engaged therewith, and after a determined time period, stopping the application of heat from the heating element and stress from a second part of the device to reduce the temperature of the constrained feature below the determined processing temperature.

[0047] Clause 12: The method described in any one of Clauses 1-11 further includes measuring the remodeling characteristics of the aluminum alloy part to determine whether the remodeling characteristics are within dimensional tolerances.

[0048] Clause 13: An apparatus comprising a first portion arranged to constrain a nonconforming feature of an aluminum alloy part against stress applied to the feature, and a second portion arranged to apply stress to the constrained feature, wherein the constrained feature is heated to a processing temperature corresponding to the identified yield strength of a specified aluminum alloy part, and the stress is applied to the constrained feature for a period of time, the period of time being a function of stress and processing temperature, in order to reshape the constrained feature within dimensional tolerances.

[0049] Clause 14: The device described in Clause 13, wherein the first portion is fitted to the aluminum alloy part to restrain the non-conforming features of the aluminum alloy part against stress applied to the feature.

[0050] Clause 15: The apparatus described in Clause 13 or 14, wherein the first and second portions are operatively coupled to reshape nonconforming features within the dimensional tolerance by approximately 5 to 500 inches.

[0051] Clause 16: The device described in any one of Clauses 13-15, wherein the first portion is arranged to constrain a nonconforming feature having a thickness between about 40 per thousand and about 150 inches.

[0052] Clause 17: The apparatus described in any one of Clauses 13-16 further includes a heating element arranged to heat the constrained features to a processing temperature.

[0053] Clause 18: The apparatus described in Clause 17, wherein the heating element is arranged to heat the constrained features to a processing temperature between about 200°F and about 400°F for a period of time between about 0.5 hours and about 32 hours.

[0054] Clause 19: The apparatus described in Clause 17 or 18, wherein after the time period, the second part is arranged to stop applying stress to the constrained feature, and the heating element is arranged to stop applying heat so as to reduce the temperature of the constrained feature below the processing temperature.

[0055] Clause 20: The device described in any one of Clauses 13-19, wherein the second part is arranged to apply a stress between about 10,000 pounds per square inch and about 65,000 pounds per square inch.

[0056] Benefiting from the teachings presented in the foregoing description and related drawings, those skilled in the art to which this disclosure pertains will conceive of numerous modifications and other instances of the disclosure set forth herein. Therefore, it should be understood that this disclosure is not limited to the specific instances disclosed, and that modifications and other instances are intended to be included within the scope of the appended claims. Furthermore, although the foregoing description and related drawings describe instances in the context of certain combinations of elements and functions, it should be recognized that, without departing from the scope of the appended claims, different combinations of elements and / or functions may be provided by alternative instances. In this regard, for example, combinations of elements and / or functions different from those explicitly described above, as set forth in some of the appended claims, are also contemplated. Although specific terms are used herein, they are used only in a general and descriptive sense and not for limiting purposes.

Claims

1. A method (200), the method comprising: Determine the yield strength of the specified aluminum alloy part (104) as a function of temperature; Determine the stress to be applied to the non-conforming feature (102) of the aluminum alloy part (104) in order to restore the non-conforming feature (102) to dimensional tolerances; The stress is correlated with the identified yield strength to determine the processing temperature of the aluminum alloy part after the stress is applied to the feature (102); Determine the time period during which the stress is applied to the feature (102) at a determined processing temperature, the time period being a function of at least the stress and the determined processing temperature; The stress is applied to the feature (102) of the aluminum alloy part (104), the feature (102) is constrained to resist the stress, the feature (102) is heated to the determined processing temperature, and the stress and heat are maintained on the feature (102) for the duration of the time period in order to realign the constrained feature (102) within the dimensional tolerance. and The non-conforming feature (102) is constrained in the first part (106) of the device (100), and the stress is applied to the constrained feature using the second part (108) of the device (100); and The first portion (106) is arranged to adapt to one or more aluminum alloy parts (104) of different shapes, sizes and cross sections, or is arranged to receive the aluminum alloy parts (104) and form the features (102) into a shape different from the desired shape, such that the natural relaxation of the aluminum results in the desired shape.

2. The method of claim 1, wherein determining the stress comprises calculating the stress based on the force to be applied to the feature (102) per unit area.

3. The method of claim 1, wherein identifying the yield strength comprises identifying two or more yield strengths as a function of temperature.

4. The method of claim 3, wherein associating the stress with the identified yield strength comprises associating the stress with the two or more identified yield strengths to determine the processing temperature of the aluminum alloy part (104) after the stress is applied to the feature (102), and wherein: If the stress is less than each of the two or more identified yield strengths, then the processing temperature is the temperature corresponding to the lower of the two identified yield strengths; and If the stress is greater than one of the identified yield strengths but less than the other of the identified yield strengths, then the processing temperature is the temperature corresponding to the higher of the two identified yield strengths.

5. The method according to claim 1, wherein determining the yield strength comprises determining the yield strength of the aluminum alloy part (104) as a function of temperature, the aluminum alloy part (104) being named as at least one of the following: a malleable aluminum alloy series 2000 under T6XX, T72 or T8XX conditions; a malleable aluminum alloy series 6000 under T6XX conditions; and a malleable aluminum alloy series 7000 under T6XX, T76XX, T73XX and T74XX conditions.

6. The method of claim 1, wherein correlating the stress with the identified yield strength to determine the processing temperature comprises correlating the stress with the identified yield strength to determine a processing temperature between 200°F and 400°F.

7. The method of claim 1, wherein determining the stress comprises determining a stress to be applied to the feature (102) in order to reshape the non-conforming feature (102) within the dimensional tolerance by 0.5 to 500 inches.

8. The method of claim 1, wherein determining the time period includes determining a time period between 0.5 hours and 32 hours.

9. The method of claim 1, wherein determining the stress comprises determining a stress between 10 klb / s² and 65 klb / s².

10. The method of claim 9, further comprising heating the feature to the determined processing temperature using a heating element (110) operably coupled thereto, and after the determined time period, stopping the application of heat from the heating element (110) and the application of the stress from the second portion (108) of the device (100) to reduce the temperature of the constrained feature (102) below the determined processing temperature.

11. The method according to any one of claims 1-10, further comprising measuring the remodeling feature (102) of the aluminum alloy part to determine whether the remodeling feature (102) is within the dimensional tolerance.

12. An apparatus (100) for performing the method of claim 1, the apparatus comprising: The first part (106) is arranged to constrain the non-conforming feature (102) of the aluminum alloy part (104) against the stress applied to said feature (102); and The second part (108) is arranged to apply the stress to the constraint (102); The constrained feature (102) is heated to a processing temperature corresponding to the identified yield strength of the specified aluminum alloy part (104), and the stress is applied to the constrained feature (102) for a period of time, the period of time being a function of the stress and the processing temperature, so as to reshape the constrained feature (102) within dimensional tolerances.

13. The apparatus of claim 12, wherein the first portion (106) is fitted to the aluminum alloy part (104) to restrain the non-conforming feature (102) of the aluminum alloy part (104) from stress applied to the feature (102).

14. The apparatus of claim 12, wherein the first portion (106) and the second portion (108) are operatively coupled to reshape the non-conforming feature (102) within the dimensional tolerance by 0.5 to 500 inches.

15. The apparatus of claim 12, wherein the first portion (106) is arranged to constrain the nonconforming feature (102) having a thickness between 40 and 150 inches.

16. The apparatus of claim 12, further comprising a heating element (110) arranged to heat the constrained feature (102) to the processing temperature.

17. The apparatus of claim 16, wherein the heating element (110) is arranged to heat the constrained feature (102) to a processing temperature between 200°F and 400°F for a period of time between 0.5 hours and 32 hours.

18. The apparatus of claim 16, wherein after the time period, the second portion is arranged to stop applying stress to the constraint feature (102), and the heating element (110) is arranged to stop applying heat so as to reduce the temperature of the constraint feature (102) below the processing temperature.

19. The apparatus according to any one of claims 12-18, wherein the second portion (108) is arranged to apply a stress between 10,000 lbs per square inch and 65,000 lbs per square inch.

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