Method and apparatus for repairing non-conforming features of aluminum alloy components

Abstract

To provide a method and apparatus for remedying a non-conforming feature of an aluminum alloy part.SOLUTION: The method comprises: identifying a yield strength as a function of temperature for a designation of an aluminum alloy part; determining a stress to be applied to a feature to re-form the non-conforming feature to within a dimensional tolerance; correlating the stress with the identified yield strength to determine a process temperature of a part upon applying the stress to the feature; determining a duration for applying the stress to the feature at the determined process temperature; and applying the stress to the feature of the part, the feature being restrained to oppose the stress, while heating the feature to the determined process temperature; and maintaining the application of the stress and the heat to the feature for the duration in order to reform the restrained feature to within the dimensional tolerance.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present disclosure relates generally to aluminum alloy components, and more particularly to methods and apparatus for repairing non-conforming features of aluminum alloy components. [Background technology]

[0002] Wrought aluminum alloy parts are known to retain residual material stresses after being machined to a shape. These residual material stresses can cause bending, twisting, or warping of one or more features in the final part, resulting in dimensional non-conformity of one or more features. In applications where tight dimensional tolerances must be met (e.g., aircraft manufacturing), non-conformity of one or more features in aluminum alloys is often problematic.

[0003] Typical repair methods for non-conforming features on aluminum alloy parts include, for example, adding shims to fill gaps or adding weight to reshape the non-conforming features on the aluminum alloy part to within dimensional tolerances. In some extreme cases, the aluminum alloy part is actually scrapped, which often impacts delivery schedules and adds significant time and cost to rework the part. In other situations, features on the aluminum alloy part are subjected to additional heat treatment, where the aluminum alloy part is heated to a processing temperature and then reshaped while the part remains at the processing temperature. However, reshaping the aluminum alloy part at the processing temperature can result in degradation of the material properties of the aluminum alloy part (i.e., reduced mechanical performance), and in some cases, the reshaped aluminum alloy part still needs to be scrapped.

[0004] Therefore, a need exists to remediate non-conforming features in aluminum alloy parts without sacrificing mechanical performance while still meeting specific dimensional tolerances. Summary of the Invention

[0005] The present disclosure is directed to a method and apparatus for repairing a non-conforming feature of an aluminum alloy component. One embodiment of the present disclosure is directed to a method including: identifying a yield strength as a function of temperature for a designation of the aluminum alloy component; determining a stress to be applied to the non-conforming feature to reform the non-conforming feature of the aluminum alloy component within dimensional tolerances; relating the stress to the identified yield strength to determine a processing temperature of the aluminum alloy component at which to stress the feature; determining a duration for stressing the feature at the determined processing temperature, the duration being a function of at least the stress and the determined processing temperature; stressing the feature while heating the feature of the aluminum alloy component to the determined processing temperature, wherein the feature is restrained against the stress; and maintaining the application of stress and heat to the feature for the duration to reform the restrained feature within dimensional tolerances.

[0006] The present disclosure further provides, in another embodiment, an apparatus for countering applied stress to a mismatched feature of an aluminum alloy component, the apparatus comprising: a first portion configured to inhibit the feature; and a second portion configured to apply stress to the inhibited feature; wherein the inhibited feature is heated to a processing temperature corresponding to a yield strength specified for the aluminum alloy component design; and wherein stress is applied to the inhibited feature for a duration that is a function of the stress and the processing temperature to reform the inhibited feature within dimensional tolerances.

[0007] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements presented in the disclosure or recited in any one or more of the claims, whether such features or elements are explicitly combined or otherwise recited in the description of a particular embodiment or in the claims herein. The present disclosure is intended to be read holistically, and any separable features or elements of the disclosure should be considered as intended to be combinable in any of its aspects and embodiments, unless the context of the disclosure clearly dictates otherwise.

[0008] Having thus described embodiments of the present disclosure in general terms, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0009] [Figure 1] 1 illustrates an apparatus for repairing non-conforming features in an aluminum alloy component. [Figure 2] 1 illustrates a method for repairing non-conforming features in an aluminum alloy part. DETAILED DESCRIPTION OF THE INVENTION

[0010] Some embodiments of the present disclosure are described in more detail below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of the present disclosure. Indeed, various embodiments of the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be comprehensive and complete, and will fully convey the scope of the disclosure to those skilled in the art. For example, unless otherwise specified, referring to something as a "first," "second," etc. should not be construed as implying a particular order. Furthermore, (unless otherwise specified) when something is described as being above another, it may instead be below, and vice versa. Similarly, when something is described as being to the left of another, it may instead be to the right, and vice versa. Like reference numbers refer to like elements throughout.

[0011] Embodiments of the present disclosure are directed to methods and apparatus for modifying non-conforming features in aluminum alloy parts. As disclosed herein, the methods and apparatus are used in aerospace applications to modify non-conforming features (e.g., stiffeners, parallel faces, etc.) in aluminum alloys. However, the methods and apparatus disclosed herein can also be used in any application where one or more features of a wrought or cast aluminum alloy part need to be reshaped to a desired dimensional tolerance. As used herein, "dimensional tolerance" refers to the amount by which a given dimensional or geometric characteristic of a feature can vary without affecting the mechanical performance of the aluminum alloy part. The dimensional tolerance is selected depending on the use of the part. Parts used in aerospace applications require close dimensional fit and have narrow dimensional tolerance ranges. Generally, dimensional tolerances are set during the design phase of the part. Therefore, as used herein, "dimensional tolerance" is determined prior to performing the methods of the present disclosure.

[0012] Aluminum alloy parts are typically formed using conventional forming methods (e.g., rolling, casting, machining, etc.). However, in some cases, one or more features of the formed aluminum alloy part do not conform within desired dimensional tolerances. This is due, for example, to residual stresses retained by the aluminum alloy part while it is being formed or fabricated. These stresses often cause bending, twisting, and / or warping of the aluminum alloy part, thereby leading to dimensional nonconformities or deviations from specified dimensional tolerances. Dimensional nonconformities often appear in areas that previously conformed due to small changes in manufacturing or processing methods. Therefore, the disclosed method and apparatus repair one or more nonconforming features of an aluminum alloy part, sometimes inhibited, by heating the nonconforming feature(s) to a processing temperature corresponding to a specified yield strength for the aluminum alloy part's design and stressing the inhibited feature(s) for a duration to reform the inhibited feature(s) within dimensional tolerances. The duration is a function of at least the stress and processing temperature.

[0013] In some exemplary cases, a thermally activated elastic straightening or "pseudo-creep" mechanism is used to elastically deform a non-conforming feature of an aluminum alloy part to conform within a desired dimensional tolerance. The thermally activated elastic straightening mechanism is activated when the non-conforming feature of the aluminum alloy part is exposed to heat and stress. This stress is less than the yield strength of the aluminum alloy. Once activated, the thermally activated elastic straightening mechanism allows the non-conforming feature to move a reforming distance within the desired dimensional tolerance without sacrificing mechanical performance.

[0014] 1 illustrates an apparatus 100 for repairing a non-conforming feature 102 in an aluminum alloy part 104. The aluminum alloy part 104, in certain embodiments, includes a part, component, module, product, and / or any other element formed from a wrought or cast aluminum alloy part. For example, the aluminum alloy part 104 may have the designation Wrought Aluminum Alloy Series 2000 in the T6XX, T72, or T8XX condition, Wrought Aluminum Alloy Series 6000 in the T6XX condition, and Wrought Aluminum Alloy Series 7000 in the T6XX, T76XX, T73XX, and T74XX conditions.

[0015] In one aspect, the apparatus 100 includes a first portion 106 configured to restrain the non-conforming feature 102 of the aluminum alloy part 104 to oppose the stress applied to the feature 102. For example, the first portion 106 may include a vice, clamp, platen, or the like, which may be positioned against the aluminum alloy part 104 to restrain the non-conforming feature 102 and oppose the stress applied to the feature 102. In this example, the first portion 106 is capable of restraining the non-conforming feature 102 of a part 104 having a thickness between about 40 thousandths of an inch and about 150 thousandths of an inch; however, other part thicknesses are contemplated by this disclosure.

[0016] The first portion 106, in some aspects, can conform to the aluminum alloy part 104 to restrain the feature 102 to counteract stresses applied to the non-conforming feature 102. For example, as illustrated in FIG. 1 , the first portion 106 has a cross-sectional shape (e.g., an inverted "L") that is complementary to a cross-sectional shape, such as an inverted "T" shape, of the aluminum alloy part 104, such that a horizontal portion of the "T" shape is restrained to counteract stresses applied to the non-conforming feature 102 (e.g., a 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 non-conforming feature 102 reforms back to a configuration perpendicular to the horizontal portion of the "T" shape, an end of the first portion 106 directly contacts the non-conforming feature 102 to counteract stresses applied to the feature 102.

[0017] In some other aspects, the first portion 106 is configured to conform to one or more aluminum alloy components of various shapes, sizes, and cross-sections, or is configured to receive the aluminum alloy component 104, and "over-forms" or forms the feature 102 into a shape other than the desired shape, such that the natural relaxation of the aluminum results in the desired shape (e.g., fits within dimensional tolerances).

[0018] In some embodiments, the apparatus 100 further comprises a second portion 108 configured to apply a stress to the restrained feature 102. For example, the second portion 108 is configured to apply a stress sufficient to reshape the non-conforming feature 102 within dimensional tolerances. This stress (σ) is determined by calculating the applied force (F) per unit area (A) (Equation 1): Equation 1: σ = F / A where F is measured in Newtons, A is measured in square meters, and σ is measured in N or Pascals (Pa) per square meter.

[0019] However, prior to determining the stress, the features 102 of the aluminum alloy part 104 are measured to determine if they are within dimensional tolerance. In some particular embodiments, the methods and apparatus described herein are capable of reforming (or moving) non-conforming features to within the desired dimensional tolerance by a reforming distance of about 5 / 1000 to 500 / 1000 inches. However, other distances shorter or longer than about 5 / 1000 to 500 / 1000 inches are also contemplated by the present disclosure.

[0020] If the measurement of the feature (e.g., feature 102) conforms 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 the feature does not conform to the desired dimensional tolerance, one or more yield strengths are identified or selected as a function of temperature for the aluminum alloy part 104 designation. The yield strength indicates the aluminum alloy part's elastic limit, or the maximum extent to which a non-conforming feature can be stretched without permanently changing its size or shape. Because different aluminum alloy parts have different shapes and, therefore, elastic limits, the identified yield strength or strengths will vary depending at least on the part's geometry, the aluminum alloy part designation (e.g., T6XX), the part's thickness, and the corresponding temperature. In some aspects, a known materials database (e.g., ASM International's ASM Alloys Center Database™) is accessed to identify the yield strength associated with the aluminum alloy part designation and determine the corresponding processing temperature and duration.

[0021] For example, known materials databases include wrought aluminum alloy series 2000 in the T6XX, T72, or T8XX condition refined between 200 and 400°F at 10 to 50 kilopounds per square inch (ksi) for 30 minutes to 32 hours for sections up to 7 inches thick; wrought aluminum alloy series 6000 in the T6XX condition refined between 200 and 400°F at 10 to 38 kilopounds per square inch (ksi) for 45 minutes to 32 hours for sections up to 7 inches thick; and wrought aluminum alloy series 7000 in the T6XX, T76XX, T73XX, and T74XX conditions refined between 200 and 375°F at 10 to 65 kilopounds per square inch (ksi) for 30 minutes to 32 hours for parts up to 10 inches thick. For comparison, in some exemplary embodiments, two different yield strengths of the aluminum alloy component designation are specified at "low" and "high" temperatures (e.g., 200°F and 375 / 400°F), with the corresponding yield strengths varying as a function of temperature. If desired, additional yield strengths (e.g., three, four, five, six, etc.) of the aluminum alloy designation are also specified as a function of temperature.

[0022] Once the yield strengths are identified, the calculated stress (i.e., the stress from Equation 1) is correlated to the identified yield strengths to determine the processing temperature of the aluminum alloy component 104. Depending on how many yield strengths are identified (i.e., one yield strength, two yield strengths, three yield strengths, etc.), correlating the stress to the identified yield strengths to determine the processing temperature may include correlating the stress to one yield strength, two yield strengths, three yield strengths, four yield strengths, etc. More specifically, the calculated stress is compared to the identified yield strength(s) to determine whether the calculated stress is less than the one or more yield strengths. If the calculated stress is less than at least one of the one or more identified yield strengths, the calculated stress can be used to reform the non-conforming feature 102. This is due to a thermally activated elastic straightening mechanism. Thus, and based on available aluminum alloy designations, calculated stresses are generally between about 10 kilopounds per square inch and about 65 kilopounds per square inch.

[0023] Based on correlating the stress with one specified yield strength, two specified yield strengths, three specified yield strengths, etc., the processing temperature (the temperature to which the part is heated to reform the non-conforming feature in conjunction with the applied stress) can be determined as the temperature corresponding to the specified yield strength. In one particular embodiment, if the stress is less than each of two or more specified yield strengths, the processing temperature is the temperature corresponding to the lower of the two specified yield strengths. In another particular embodiment, if the stress is greater than one of the specified yield strengths but less than the other of the specified yield strengths, the processing temperature is the temperature corresponding to the higher of the two specified yield strengths. For example, the stress calculated by Equation 1 is related to or compared to the yield strength at each selected temperature (e.g., a "low" temperature (e.g., 200°F) and a "high" temperature (e.g., 375 / 400°F)) and determined to be lower than both the low and high temperatures. Thus, in this example, the processing temperature is determined to be the temperature corresponding to the lower of the two specified yield strengths, or the "low" temperature (e.g., 200°F). Thus, and based on available aluminum alloy designations, processing temperatures are generally between about 200°F and about 400°F.

[0024] Once the processing temperature is determined, the duration for applying stress to the feature 102 at the determined processing temperature is then determined. The duration is at least a function of the stress and the determined processing temperature. However, in some embodiments, there are other variables that affect the duration, such as, for example, the reforming distance and the thickness of the part. In some particular embodiments, the duration is a time corresponding to a specified yield strength and processing temperature for the designation of the aluminum alloy part 104. For example, the duration for a non-conforming feature 102 in a part 104 designated as T72 wrought aluminum alloy series 2000 is 0.5 to 32 hours, with the restrained feature 102 being monitored at regular intervals within this duration to determine if the restrained feature 102 has moved the reforming distance.

[0025] Other aspects of determining the duration include determining the duration as a function of the reforming distance, bending moment, calculated stress, and material properties of the part 104. Thus, and based on available aluminum alloy specifications, the treatment time is generally between about 0.5 hours and about 32 hours.

[0026] Once the stress, processing temperature, and duration have been determined, the non-conforming feature is ready to be reformed. It is worth noting that physical constraints of the equipment, such as processing temperature and stress uniformity, may warrant adjustment of one or more of the processing temperature, stress, and duration to efficiently and cost-effectively remedy the non-conforming feature. For example, to remedy a non-conforming feature in a large aluminum alloy part (e.g., a rib or spar), a large equipment is required. In this example, it may be advantageous to apply a "low" stress to the non-conforming feature of the large aluminum alloy part at a "high" processing temperature for a "short" duration to keep the capital cost of the equipment low. In another example, when using large equipment to remedy a non-conforming feature with a complex shape, it may be advantageous to apply a "high" stress at a "low" processing temperature for a "long" duration, thereby maintaining processing temperature uniformity throughout the aluminum alloy part, reducing the energy input required to the equipment to maintain that processing temperature, and enabling shorter processing cycle times (i.e., the time required to heat or cool the large equipment is shorter at a lower processing temperature than at a higher processing temperature). Alternatively, depending on the physical constraints of the equipment used to modify the non-conforming features, it may be advantageous to apply a "high" stress for a "short" duration at a "low" processing temperature, a "low" stress for a "long" duration at a "low" processing temperature, or a "low" stress for a "short" duration at a "low" processing temperature.

[0027] In some embodiments, the apparatus 100 includes a heating element 110 configured to heat the inhibited feature 102 to a processing temperature, as shown in FIG. 1 . In some embodiments, for example, the apparatus 100 is a furnace or other device capable of heating the part 104 to a processing temperature and maintaining the processing temperature for a determined duration. In some examples, the heating element 110 is an ignition mechanism that ignites a fuel source to generate a flame, an electrical resistance heating element, or the like. Further, in some embodiments, the heating element 110 is controllable via a control device 112 to generate sufficient heat to heat the non-conforming feature 102 to the processing temperature for a duration. The control device 112, in some embodiments, is a mechanical switch, a bellows, a non-transitory computer-readable medium, any combination thereof, or the like, and is capable of communicating with and controlling at least the heating element 110.

[0028] Thus, in some aspects, the non-conforming feature 102 is restrained in the first portion 106 of the apparatus 100, and a stress is applied to the restrained feature 102 using the second portion 108 of the apparatus 100. The feature 102 is then heated to a determined processing temperature using a heating element 110 operatively associated with the feature 102. Optionally, the feature 102 is monitored at regular intervals within a duration to determine whether the feature 102 has moved the reformation distance. Once the feature 102 has moved the reformation distance and / or after the determined duration, the application of heat from the heating element 110 and the application of stress from the second portion 108 of the apparatus 100 are stopped, and the temperature of the restrained feature 102 decreases below the determined processing temperature. In some aspects, a control device 112 is used to start, stop, and monitor the reformation of the non-conforming feature 102.

[0029] After the temperature of the restrained feature 102 decreases below the determined processing temperature, the feature 102 is removed from the first portion 106, and the reshaped feature 102 is measured for dimensional tolerance. It is important to note that the aluminum alloy part can be removed from the apparatus 100 as soon as the restrained feature 102 is heated to the processing temperature. However, it is advantageous to leave the feature 102 in place until its temperature drops below the processing temperature, because cooling reduces deformation while the feature 102 is restrained. If the feature 102 has not moved the reshaping distance, the feature 102 is restrained again, and the heating process is repeated for the determined duration at the determined processing temperature.

[0030] Alternatively, if the feature 102 is heated and restrained for only a portion of the determined duration, the feature 102 is restrained again and the heat treatment is repeated at the second treatment temperature for the remaining duration. For example, if a 6061-T6XX aluminum alloy component was treated at a first treatment temperature of 300°F for a duration of 5 hours, the 6061-T6XX aluminum alloy component may be treated at a second treatment temperature of 275°F for only a duration of 16 hours, or at a second treatment temperature of 350°F for only a duration of 1.5 hours. Thus, the method described herein is repeated to determine a second treatment temperature. The second treatment temperature is different from the initial or previously determined treatment temperature.

[0031] When the feature 102 has moved the reforming distance, the part 104 is dimensionally acceptable and usable as desired. In this manner, the first portion 106 and second portion 108 of the apparatus 100 work cooperatively to move the non-conforming feature 102 the reforming distance into within the dimensional tolerance (i.e., reform the non-conforming feature 102 by approximately 5 / 1000 to 500 / 1000 of an inch) without affecting the mechanical performance of the aluminum alloy part 104.

[0032] Referring to Figure 2, a method 200 for repairing a non-conforming feature in an aluminum alloy component is shown. The method 200 includes, as a first step 202, identifying a yield strength as a function of temperature for a specification of the aluminum alloy component. The method further includes, as a second step 204, determining a stress to be applied to the non-conforming feature to reform the non-conforming feature within dimensional tolerances. The method further includes, as a third step 206, relating the stress to the identified yield strength to determine a processing temperature for the aluminum alloy component at which the feature is stressed. The method further includes, as a fourth step 208, determining a duration for stressing the feature at the determined processing temperature. The duration is a function of at least the stress and the determined processing temperature. The method further includes, as a fifth step 210, stressing the feature of the aluminum alloy component while heating the feature to the determined processing temperature, where the feature is restrained against the stress, and maintaining the stress and heat on the feature for a duration to reform the restrained feature within dimensional tolerances.

[0033] Clause 1 1. A method comprising: identifying a yield strength as a function of temperature for a designation of an aluminum alloy part; determining a stress to be applied to a non-conforming feature of the aluminum alloy part to reform the feature within a dimensional tolerance; relating the stress to the identified yield strength to determine a processing temperature of the aluminum alloy part at which the feature will be stressed; determining a duration for applying the stress to the feature at the determined processing temperature, the duration being a function of the stress and the determined processing temperature; applying the stress to the feature while heating the feature of the aluminum alloy part to the determined processing temperature, the feature being restrained against the stress; and maintaining the application of the stress and heat to the feature for the duration to reform the restrained feature within the dimensional tolerance.

[0034] Clause 2 10. The method of claim 1, wherein determining the stress includes calculating the stress based on a force to be applied to the feature per unit area.

[0035] Clause 3 3. The method of any one of clauses 1 to 2, wherein determining the yield strength comprises determining two or more yield strengths as a function of temperature.

[0036] Clause 4 4. The method of claim 3, wherein relating the stress to the identified yield strengths comprises relating the stress to the two or more identified yield strengths to determine the processing temperature of the aluminum alloy component when applying the stress to the feature, wherein if the stress is lower 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.

[0037] Clause 5 5. The method of any one of clauses 1 to 4, wherein determining the yield strength comprises determining the yield strength as a function of temperature for the aluminum alloy component having at least one of the following designations: wrought aluminum alloy series 2000 in the T6XX, T72, or T8XX condition; wrought aluminum alloy series 6000 in the T6XX condition; and wrought aluminum alloy series 7000 in the T6XX, T76XX, T73XX, and T74XX conditions.

[0038] Clause 6 6. The method of any one of clauses 1-5, wherein relating the stress to the identified yield strength to determine the processing temperature comprises relating the stress to the identified yield strength to determine a processing temperature between about 200°F and about 400°F.

[0039] Clause 7 7. The method of any one of clauses 1 to 6, wherein determining the stress includes determining the stress to be applied to a non-conforming feature to reform the feature to within the dimensional tolerance by approximately 5 thousandths to 500 thousandths of an inch.

[0040] Article 8 8. The method of any one of clauses 1 to 7, wherein determining the duration comprises determining a duration of between about 0.5 hours and about 32 hours.

[0041] Article 9 9. The method of any one of clauses 1 to 8, wherein determining the stress includes determining a stress of from about 10 kilopounds per square inch to about 65 kilopounds per square inch.

[0042] Article 10 10. The method of any one of clauses 1 to 9, further comprising restraining the non-conforming feature in a first portion of an apparatus and applying the stress to the restrained feature using a second portion of the apparatus.

[0043] Article 11 11. The method of claim 10, further comprising: heating the feature to the determined processing temperature using a heating element operatively associated with the feature; and ceasing the application of heat from the heating element and the application of stress from the second part of the apparatus after the determined duration to reduce the temperature of the inhibited feature below the determined processing temperature.

[0044] Article 12 12. The method of any one of clauses 1 to 11, further comprising measuring the reshaped feature of the aluminum alloy part to determine if the reshaped feature is within the dimensional tolerance.

[0045] Article 13 1. An apparatus comprising: a first portion configured to restrain a mismatched feature of an aluminum alloy component to counteract a stress applied to the feature; and a second portion configured to apply the stress to the restrained feature; wherein the restrained feature is heated to a processing temperature corresponding to a specified yield strength for the aluminum alloy component design; and the stress is applied to the restrained feature for a duration that is a function of the stress and the processing temperature to reform the restrained feature within dimensional tolerances.

[0046] Article 14 14. The apparatus of claim 13, wherein the first portion is conformable to the non-conforming feature of the aluminum alloy part to inhibit the feature from opposing the stress applied to the feature.

[0047] Article 15 15. The apparatus of clause 13 or 14, wherein the first part and the second part operatively cooperate to reform the non-conforming feature to within the dimensional tolerance by about 5 thousandths to 500 thousandths of an inch.

[0048] Article 16 16. The apparatus of any one of clauses 13 to 15, wherein the first portion is configured to inhibit the non-conforming feature having a thickness between about 40 thousandths of an inch and about 150 thousandths of an inch.

[0049] Article 17 17. The apparatus of any one of clauses 13 to 16, further comprising a heating element configured to heat the inhibited feature to the processing temperature.

[0050] Article 18 18. The apparatus of clause 17, wherein the heating element is configured to heat the inhibited feature to a processing temperature of between about 200°F and about 400°F for a duration of between about 0.5 hours and about 32 hours.

[0051] Article 19 19. The apparatus of clause 17 or 18, wherein the second portion is configured to stop applying stress to the arrested feature, and the heating element is configured to stop applying heat after the duration to reduce the temperature of the arrested feature to a temperature below the processing temperature.

[0052] Article 20 20. The apparatus of any one of clauses 13 to 19, wherein the second portion is configured to apply a stress of about 10 kilopounds per square inch to about 65 kilopounds per square inch.

[0053] Numerous modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. It is to be understood, therefore, that the disclosure is not limited to the particular embodiments disclosed, and that variations and other embodiments are intended to be included within the scope of the appended claims. Furthermore, while the foregoing description and accompanying drawings describe embodiments with reference to particular exemplary combinations of elements and / or functions, it is to be understood that alternative embodiments may provide various combinations of elements and / or functions without departing from the scope of the appended claims. That is, other combinations of elements and / or functions than those expressly set forth above are also contemplated, for example, as may be set forth in some of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. A method (200) comprising: Determining the yield strength as a function of temperature for a specified aluminum alloy component (104); determining a stress to be applied to the non-conforming feature (102) of the aluminum alloy component (104) to reshape the non-conforming feature (102) within dimensional tolerances; relating the stress to the identified yield strength to determine a processing temperature for the aluminum alloy component when applying the stress to the feature (102); determining a duration for applying the stress to the feature (102) at the determined processing temperature, the duration being a function of at least the stress and the determined processing temperature; applying the stress to the feature (102) of the aluminum alloy component (104) while heating the feature (102) to the determined processing temperature, the feature (102) being restrained to oppose the stress, and maintaining the application of the stress and heat to the feature (102) for the duration to reform the restrained feature (102) within the dimensional tolerance. A method (200) comprising:

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

3. The method of claim 1 or 2, wherein determining the yield strength comprises determining two or more yield strengths as a function of temperature.

4. Correlating the stress to the identified yield strengths includes correlating the stress to the two or more identified yield strengths to determine the processing temperature of the aluminum alloy component (104) when applying the stress to the feature (102); if the stress is less than each of the two or more specified yield strengths, the processing temperature is the temperature corresponding to the lower of the two specified yield strengths; 4. The method of claim 3, wherein if the stress is greater than one of the specified yield strengths but less than the other of the specified yield strengths, the processing temperature is the temperature corresponding to the higher of the two specified yield strengths.

5. 5. The method of any one of claims 1 to 4, wherein determining the yield strength comprises determining the yield strength as a function of temperature for the aluminum alloy component (104) having at least one designation of Wrought Aluminum Alloy Series 2000 in a T6XX, T72, or T8XX condition, Wrought Aluminum Alloy Series 6000 in a T6XX condition, and Wrought Aluminum Alloy Series 7000 in a T6XX, T76XX, T73XX, and T74XX condition.

6. 6. The method of claim 1, wherein relating the stress to the identified yield strength to determine the processing temperature comprises relating the stress to the identified yield strength to determine a processing temperature between about 200°F (93.3°C) and about 400°F (204.4°C).

7. 7. The method of claim 1, wherein determining the stress comprises determining the stress to be applied to the non-conforming feature to reshape the feature by approximately 0.127 mm (0.5 to 500 thousandths of an inch) to within the dimensional tolerance.

8. 8. The method of claim 1, wherein determining the duration comprises determining a duration between about 0.5 hours and about 32 hours.

9. 9. The method of claim 1, wherein determining the stress comprises determining a stress of from about 10 kilopounds per square inch (ksi) to about 65 kilopounds per square inch (ksi).

10. 10. The method of claim 1, further comprising restraining the non-conforming feature in a first portion of an apparatus, and applying the stress to the restrained feature using a second portion of the apparatus.

11. The method of claim 10, further comprising: heating the feature to the determined processing temperature using a heating element (110) operably associated with the feature; and, after the determined duration, ceasing the application of heat from the heating element (110) and the application of stress from the second part (108) of the apparatus (100) so as to reduce the temperature of the inhibited feature (102) below the determined processing temperature.

12. 12. The method of any one of claims 1 to 11, further comprising measuring the reshaped feature (102) of the aluminum alloy component to determine if the reshaped feature (102) is within the dimensional tolerance.

13. An apparatus (100), comprising: a first portion (106) configured to restrain the non-conforming feature (102) of the aluminum alloy part (104) to oppose stress applied to the feature (102); and a second portion (108) configured to apply said stress to said restrained feature (102); Equipped with 1. An apparatus (100) in which the restrained feature (102) is heated to a processing temperature corresponding to a yield strength specified for the aluminum alloy component (104) designation, and the stress is applied to the restrained feature (102) for a duration to reform the restrained feature (102) within dimensional tolerances, the duration being a function of the stress and the processing temperature.

14. 14. The apparatus of claim 13, wherein the first portion is conformable to the aluminum alloy component to restrain the non-conforming feature of the aluminum alloy component against the stress applied to the feature.

15. 15. The apparatus of claim 13 or 14, wherein the first portion (106) and the second portion (108) operatively cooperate to reshape the non-conforming feature (102) by approximately 0.127 mm (0.5 to 12.7 mm) to within the dimensional tolerance.

16. 16. The apparatus of any one of claims 13 to 15, wherein the first portion (106) is configured to restrain the non-conforming feature (102) having a thickness between about 40 thousandths of an inch and about 150 thousandths of an inch.

17. The apparatus of any one of claims 13 to 16, further comprising a heating element (110) configured to heat the inhibited feature (102) to the processing temperature.

18. 18. The apparatus of claim 17, wherein the heating element (110) is configured to heat the inhibited feature (102) to a processing temperature of between about 93.3°C (200°F) and about 204.4°C (400°F) for a duration of between about 0.5 hours and about 32 hours.

19. 18. The apparatus of claim 17, wherein the second portion is configured to stop applying stress to the inhibited feature (102), and the heating element (110) is configured to stop applying heat after the duration to reduce the temperature of the inhibited feature (102) to a temperature below the processing temperature.

20. 20. The apparatus of any one of claims 13 to 19, wherein the second portion (108) is configured to apply a stress of from about 6.8948 x 107 Pascals (10 kilopounds per square inch (ksi)) to about 4.48159 x 108 Pascals (65 kilopounds per square inch).

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