Hybrid structure including built-up sandwich structure and monolithic SPF/DB structure

Patent metadata

Field	Value
Publication number	US-9623977-B2
Application number	US-201414220821-A
Country	US
Kind code	B2
Filing date	Mar 20, 2014
Priority date	Mar 20, 2014
Publication date	Apr 18, 2017
Grant date	Apr 18, 2017

Abstract

A hybrid structure comprises a metallic built-up sandwich structure, and a monolithic superplastic formed and diffusion bonded structure joined to the built-up sandwich structure.

First claim

The invention claimed is:

1. A hybrid structure comprising:
a metallic built-up sandwich structure; and
a monolithic superplastic formed and diffusion bonded (SPF/DB) structure joined to the built-up sandwich structure, wherein at least a non-joining portion of the SPF/DB structure has a reduced thickness relative to the built-up sandwich structure.

2. The hybrid structure of claim 1 , wherein the SPF/DB structure has a complex contour.

3. The hybrid structure of claim 1 , wherein the SPF/DB structure has a forming radius of curvature of less than six inches.

4. The hybrid structure of claim 1 , wherein the built-up sandwich structure and the SPF/DB structure are joined by direct physical contact.

5. The hybrid structure of claim 1 , wherein a joint between the built-up sandwich structure and the SPF/DB structure has localized strengthening.

6. The hybrid structure of claim 5 , wherein the localized strengthening includes a thickness pad up of the SPF/DB structure.

7. The hybrid structure of claim 5 , wherein the localized strengthening includes a shear strip joining the SPF/DB structure to the built-up sandwich structure.

8. The hybrid structure of claim 1 , wherein the built-up sandwich structure includes first and second face sheets and a core of metallic ribbons joined between the face sheets.

9. The hybrid structure of claim 1 , wherein at least one of the SPF/DB structure and the built-up sandwich structure is treated for noise attenuation.

10. The hybrid structure of claim 9 , wherein the SPF/DB structure includes face sheets and a core that forms cells; and wherein at least one of the face sheets has a plurality of openings for allowing noise and air to enter into the cells.

11. The hybrid structure of claim 10 , wherein the core includes a perforated septum.

12. The hybrid structure of claim 10 , wherein cells are pyramid-shaped.

13. The structure of claim 1 , wherein the built-up sandwich structure and the SPF/DB structure form an inner wall of an engine nacelle fan duct; wherein face sheets of the built-up sandwich structure have a plurality of openings for noise attenuation; and wherein the SPF/DB structure accommodates bifurcations.

14. The structure of claim 1 , wherein the built-up sandwich structure and the SPF/DB structure are configured as a bleed air duct.

15. The structure of claim 1 , wherein the built-up sandwich structure forms an annular portion of an engine plug, and wherein the SPF/DB structure forms a conical portion of the engine plug.

16. The structure of claim 1 , wherein the built-up sandwich structure forms a convergent portion of a nozzle, and wherein the SPF/DB structure forms a throat and divergent section of the nozzle.

17. An engine nacelle fan duct comprising an inner wall including a metallic built-up sandwich structure joined by a monolithic SPF/DB structure, wherein at least a non-joining portion of the SPF/DB structure has a reduced thickness relative to the built-up sandwich structure and the SPF/DB structure accommodating a bifurcation.

18. A method of constructing a hybrid structure, the method comprising:
forming a monolithic SPF/DB structure;
joining the SPF/DB structure to a metallic built-up sandwich structure; and
reducing a thickness of at least a non-joining portion of the SPF/DB structure relative to the built-up sandwich structure.

Assignees

• Boeing Co

Inventors

• Runyan Max R
• Sanders Daniel G
• Mauldin Jack W
• Ludwig Brent C
• Comfort John M
• Hefti Larry D
• Joel Jason F

Classifications

• B32B3/12

  characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure · CPC title

• F02K1/827

  Sound absorbing structures or liners · CPC title

• B32B2605/00

  Vehicles · CPC title

• Y10T428/12389

  having variation in thickness · CPC title

• F05D2260/963

  by Helmholtz resonators · CPC title