Panel and method of forming a three-sheet panel

Patent metadata

Field	Value
Publication number	US-10569504-B2
Application number	US-201715443235-A
Country	US
Kind code	B2
Filing date	Feb 27, 2017
Priority date	Feb 27, 2017
Publication date	Feb 25, 2020
Grant date	Feb 25, 2020

Abstract

A panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.

First claim

What is claimed is:

1. A method of forming an expanded three-sheet panel, the method comprising:
selecting a first face sheet made of a first thermal expansion material that has a first coefficient of thermal expansion between about 4.0 ppm/° F. and about 5.5 ppm/° F.;
selecting a second face sheet made of a second thermal expansion material that is different from the first thermal expansion material and that has a second coefficient of thermal expansion between about 7 ppm/° F. and about 10 ppm/° F.;
attaching each of the selected first and second face sheets to a core sheet to sandwich the core sheet between the first and second face sheets to provide a precursor panel; and
processing the precursor panel to form the expanded three-sheet panel.

2. The method of claim 1 wherein selecting the first face sheet made of the first thermal expansion material includes selecting material of the first face sheet to be an iron alloy comprising 35.0 wt % to 40.0 wt % nickel, 12.0 wt % to 16.0 wt % cobalt, 4.3 wt % to 5.2 wt % niobium, and 1.3 wt % to 1.8 wt % titanium.

3. The method of claim 1 wherein selecting the second face sheet made of the second thermal expansion material includes selecting material of the second face sheet to be a nickel alloy comprising at least 58.0 wt % nickel, 20.0 wt % to 23.0 wt % chromium, at most 5.0 wt % iron, 8.0 wt % to 10.0 wt % molybdenum, and 3.15 wt % to 4.15 wt % niobium.

4. The method of claim 1 further comprising:
selecting the core sheet with a thickness that is greater than thickness of each of the selected first and second face sheets.

5. The method of claim 4 wherein selecting the core sheet with a thickness that is greater than thickness of each of the selected first and second face sheet includes selecting material of the core sheet to be a nickel alloy comprising at least 58.0 wt % nickel, 20.0 wt % to 23.0 wt % chromium, at most 5.0 wt % iron, 8.0 wt % to 10.0 wt % molybdenum, and 3.15 wt % to 4.15 wt % niobium.

6. The method of claim 1 wherein attaching each of the selected first and second face sheets to a core sheet to sandwich the core sheet between the first and second face sheets to provide a precursor panel includes welding each of the selected first and second face sheets to the core sheet to provide the precursor panel.

7. The method of claim 1 wherein the method comprises a superplastic forming method.

8. The method of claim 1 wherein selecting the first face sheet made of the first thermal expansion material includes selecting the first face sheet having a thickness between about 0.10 inches (0.025 centimeters) and about 0.125 inches (0.318 centimeters).

9. The method of claim 1 wherein selecting the second face sheet made of the second thermal expansion material includes selecting the second face sheet having a thickness between about 0.01 inches (0.025 centimeters) and about 0.125 inches (0.318 centimeters).

10. The method of claim 1 further comprising selecting the core sheet having a thickness between about 0.01 inches (0.025 centimeters) and about 0.10 inches (0.254 centimeters).

11. The method of claim 1 wherein selecting the first face sheet made of the first thermal expansion material includes selecting the first face sheet having a density between about 0.25 lbs/in 3 and about 0.40 lbs/in 3 .

12. The method of claim 1 wherein selecting the second face sheet made of the second thermal expansion material includes selecting the second face sheet having a density between about 0.25 lbs/in 3 and about 0.40 lbs/in 3 .

13. The method of claim 1 further comprising selecting the core sheet has a density between about 0.25 lbs/in 3 and about 0.40 lbs/in 3 .

14. A method of forming an expanded three-sheet panel, the method comprising:
selecting a first face sheet made of an iron alloy comprising 35.0 wt % to 40.0 wt % nickel, 12.0 wt % to 16.0 wt % cobalt, 4.3 wt % to 5.2 wt % niobium, and 1.3 wt % to 1.8 wt % titanium;
selecting a second face sheet made of a nickel alloy comprising at least 58.0 wt % nickel, 20.0 wt % to 23.0 wt % chromium, at most 5.0 wt % iron, 8.0 wt % to 10.0 wt % molybdenum, and 3.15 wt % to 4.15 wt % niobium;
selecting a core sheet made of a nickel alloy comprising at least 58.0 wt % nickel, 20.0 wt % to 23.0 wt % chromium, at most 5.0 wt % iron, 8.0 wt % to 10.0 wt % molybdenum, and 3.15 wt % to 4.15 wt % niobium;
attaching each of the selected first and second face sheets to the core sheet to sandwich the core sheet between the first and second face sheets to provide a precursor panel; and
processing the precursor panel to form the expanded three-sheet panel.

15. The method of claim 14 wherein the method comprises a superplastic forming method.

16. A method of forming an expanded three-sheet panel, the method comprising:
attaching a first face sheet and a second face sheet to a core sheet to sandwich the core sheet between the first and second face sheets, wherein the first face sheet is made of an iron alloy comprising 35.0 wt % to 40.0 wt % nickel, 12.0 wt % to 16.0 wt % cobalt, 4.3 wt % to 5.2 wt % niobium, and 1.3 wt % to 1.8 wt % titanium and the second face sheet is made of a thermal expansion material that has a coefficient of thermal expansion that is greater than the coefficient of thermal expansion of the iron alloy; and
superplastic forming the first face sheet at a different rate of expansion than the second face sheet to form the expanded three-sheet panel.

17. The method of claim 16 wherein superplastic forming the first face sheet at a different rate of expansion than the second face sheet to form the three-sheet panel includes expanding one of the first and second face sheets at a first time and then expanding the other one of the first and second face sheets at a second time which is after the first time to pull the core sheet into a desired shape.

18. The method of claim 16 wherein superplastic forming the first face sheet at a different rate of expansion than the second face sheet to form the three-sheet panel includes expanding the first and second face sheets at the same time to pull the core sheet into a desired shape.

19. The method of claim 16 wherein the first face sheet can withstand a temperature up to or above 1000° F. higher than the second face sheet without degradation of the three-sheet panel when the first face sheet is exposed to more heat than the second face sheet.

20. A method of forming an expanded three-sheet panel, the method comprising:
attaching a first face sheet and a second face sheet to a core sheet to sandwich the core sheet between the first and second face sheets, wherein the first face sheet is made of a first thermal expansion material that has a first coefficient of thermal expansion between about 4.0 ppm/° F. and about 5.5 ppm/° F. and the second face sheet is made of a second thermal expansion material that has a second coefficient of thermal expansion that is between about 7 ppm/° F and about -b 10 ppm/° F; and
superplastic forming the first face sheet at a different rate of expansion than the second face sheet to form the expanded three-sheet panel.

21. The method of claim 20 wherein the first face sheet can withstand a temperature up to or above 1000° F. higher than the second face sheet without degradation of the three-sheet panel when the first face sheet is exposed to more heat than the second face sheet.

22. The method of claim 20 wherein the core sheet has a coefficient of thermal expansion between about 7 ppm/° F. a

Assignees

• Boeing Co

Inventors

• Matsen Marc R
• Firth Lee C
• Nansen David S
• Zolnowski Michael R
• Wilkinson Carey E
• Foltz Gregory A

Classifications

• C22C19/05

  with chromium · CPC title

• B32B2307/30

  having particular thermal properties · CPC title

• B32B18/00

  Layered products essentially comprising ceramics, e.g. refractory products · CPC title

• B32B3/28 Primary

  characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) · CPC title

• B32B1/00 Primary

  Layered products having a non-planar shape · CPC title