In-situ selective reinforcement of near-net-shaped formed structures

Patent metadata

Field	Value
Publication number	US-2016228947-A1
Application number	US-201615040528-A
Country	US
Kind code	A1
Filing date	Feb 10, 2016
Priority date	Feb 10, 2015
Publication date	Aug 11, 2016
Grant date	—

Abstract

Various embodiments provide methods in which a metal matrix composite (MMC) material is incorporated into a metallic structure during a one-step near-net-shape structural forming process. Various embodiments provide in-situ selective reinforcement processes in which the MMC may be pre-placed on a forming tool in locations that correspond to specific regions in the metallic structure. Various embodiment near-net-shape structural forming processes may then be executed and result in various embodiment metallic structural components with selectively-reinforced regions that provide enhanced mechanical properties in key locations.

First claim

What is claimed is:

1 . A method of in-situ selective reinforcement, comprising:
selecting one or more location of a final structural component for reinforcement; placing a metal matrix composite (MMC) material in a forming tool at one or more location of the forming tool corresponding to the selected one or more location of the final structural component for reinforcement; and forming, from a starting stock material, the final structural component using the forming tool with the MMC material placed in it.

2 . The method of claim 1 , wherein the MMC material comprises a ceramic.

3 . The method of claim 1 , wherein the MMC material comprises one or more of aluminum, an aluminum alloy, alumina, and silicon-carbide.

4 . The method of claim 3 , wherein the MMC material is reinforced with one or more of fibers, whiskers, or particles.

5 . The method of claim 4 , wherein the MMC material is a tape.

6 . The method of claim 5 , wherein the MMC material is MetPreg™.

7 . The method of claim 5 , wherein the MMC material is an aluminum alloy with a percent weight copper.

8 . The method of claim 7 , wherein the percent weight copper is 2 percent.

9 . The method of claim 5 , wherein the thickness of the tape is from 0.018 inches to 0.180 inches.

10 . The method of claim 9 , wherein the width of the tape is from 0.375 inches to 0.48 inches.

11 . The method of claim 1 , wherein the starting stock material is a metal alloy.

12 . The method of claim 11 , wherein the starting stock material is an aluminum-lithium alloy.

13 . The method of claim 1 , the starting stock material comprises aluminum or an aluminum alloy.

14 . The method of claim 1 , wherein the forming comprises a one-step near-net-shape structural forming process.

15 . The method of claim 14 , wherein the one-step near-net-shape structural forming process comprises spin forming, flow forming, forging, or cold pressing.

16 . The method of claim 15 , wherein forming tool comprises a cylindrical mandrel.

17 . The method of claim 16 , wherein:
the MMC material comprises aluminum or an aluminum alloy; and the final structural component comprises a stiffened aluminum alloy cylinder with the MMC material bonded to a top of each stiffener the cylinder.

18 . A method of in-situ selective reinforcement, comprising:
selecting one or more location of a final structural component for reinforcement; placing a metal matrix composite (MMC) material in a forming tool at one or more location of the forming tool corresponding to the selected one or more location of the final structural component for reinforcement, wherein the MMC material comprises aluminum or an aluminum alloy; and forming, from a starting stock material, the final structural component by a one-step near-net-shape structural forming process using the forming tool with the MMC material placed in it, wherein the starting stock material comprises aluminum or an aluminum alloy.

19 . The method of claim 18 , wherein:
the MMC material is a tape; and the starting stock material is an aluminum-lithium alloy.

20 . A final structural component formed by the method of claim 19 .

Assignees

• Nasa

Inventors

• Bird Richard Keith
• Alexa Joel A
• Messick Peter L
• Domack Marcia S
• Wagner John A

Classifications

• B22D19/02 Primary

  for making reinforced articles (B22D19/14 takes precedence) · CPC title

• B22D23/00

  Casting processes not provided for in groups B22D1/00 - B22D21/00 (making metallic powder by casting B22F9/08; alumino-thermic welding B23K23/00; remelting metals C22B9/16) · CPC title

• B22D21/007

  with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C · CPC title

• B22D13/00

  Centrifugal casting; Casting by using centrifugal force · CPC title

• B21J5/00

  Methods for forging, hammering, or pressing (for working sheet-metal or metal tubes, rods, or profiles B21D; for working wire B21F); Special equipment or accessories therefor · CPC title