Superplastic Pressure Membrane Precursors to Prevent Thinning and Cracking
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Solution Overview
Problem
Pressure membranes used for consolidating composite materials face challenges in withstanding high temperatures and often experience thinning or cracking during fabrication, limiting their usability.
Innovation Solution
The development of pressure membranes with features such as regions of increased thickness and contours made from materials capable of superplastic deformation, allowing for shaping at superplastic temperatures while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If pressure membranes are shaped to desired contours during fabrication, then the membranes can conform to the composite part geometry, but the membranes experience thinning or cracking that reduces their structural integrity
Solution Approach 1:
The patent applies superplastic forming which changes the temperature parameter to enable the membrane material to undergo superplastic deformation. This allows the membrane to be shaped to complex contours while maintaining uniform thickness and avoiding cracking, as the material becomes extremely ductile at superplastic temperatures
Solution Approach 2:
The patent incorporates design features such as regions of increased thickness and contours into the membrane before forming. These preliminary design features are strategically placed to compensate for expected thinning during forming, ensuring that the final shaped membrane maintains adequate structural integrity in all regions
2Temperature
If conventional materials are used for pressure membranes, then the membranes can be fabricated, but they cannot withstand the high temperatures required for composite consolidation
Solution Approach 1:
The patent changes the temperature parameter during fabrication by using superplastic forming at elevated temperatures. This enables the use of materials that can withstand high consolidation temperatures while still allowing the membrane to be formed into the desired shape during the brief superplastic window
Solution Approach 2:
The patent employs materials that exhibit superplastic behavior, which are often composite or specially engineered alloys. These materials combine the high-temperature resistance needed for composite consolidation with the superplastic deformability needed for complex shaping
3Temperature
If pressure membranes are designed with complex features for high-temperature resistance, then the membranes can withstand consolidation temperatures, but the fabrication process becomes more difficult and prone to defects
Solution Approach 1:
The patent uses superplastic forming to change the temperature parameter during the shaping process. This enables complex features and contours to be formed in materials that can withstand high temperatures, as the superplastic state temporarily increases ductility and reduces forming forces required
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the risk of thinning and cracking, increasing the number of usable pressure membranes and saving labor and materials in composite part fabrication.
Implementation Method 1
The precursor includes features that facilitate shaping of the precursor at a superplastic temperature and are selected from the group consisting of: regions of increased thickness and contours. The material that the features are made from is capable of undergoing superplastic deformation.
Data Source
AI summary
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.