David M Schulz

US Patent:

44209584, Dec 20, 1983

Filed:

Dec 17, 1981

Appl. No.:

6/331749

Inventors:

David W. Schulz - Hermosa Beach CA
Edward D. Weisert - Rolling Hills Estates CA

Assignee:

Rockwell International Corporation - El Segundo CA

International Classification:

B21B 3708

US Classification:

72 21

Abstract:

An improvement to an apparatus for and method of making structures from at least one workpiece is disclosed. The prior art apparatus and method comprised a pair of dies which were clamped about the periphery of the at least one workpiece creating a gap therebetween. A pair of non-inflatable platens were then used to apply a force against the pair of dies further clamping the workpiece in place. The die assembly and workpiece were then heated to forming temperatures and thereafter the workpiece was formed within the pair of dies by fluid under pressure. Typically the forming was Superplastic Forming or Superplastic Forming/Diffusion Bonding. The improvement to the apparatus and method comprises providing an inflatable platen between one of the dies and one of the non-inflatable platens, adapted to regulate the force applied by said pair of dies to said at least one workpiece. A sensor, mounted within the gap is adapted to sense changes in the dimensions of the actual gap and provide a first output signal proportional thereto during the forming of the structure. A signal generator is provided for producing a second output signal proportional to a preferred gap dimension that is produced when said force is the minimum amount necessary for forming the at least one workpiece into the structure.

US Patent:

44834780, Nov 20, 1984

Filed:

Sep 11, 1981

Appl. No.:

6/301360

Inventors:

David W. Schulz - Hermosa Beach CA

Assignee:

Rockwell International Corporation - El Segundo CA

International Classification:

B23K 3102

US Classification:

228157

Abstract:

A method for fabricating superplastically formed/diffusion bonded structures wherein metal blanks of aluminum or an aluminum alloy having an oxide surface layer are joined at selected areas by diffusion bonding and expanded superplastically to form a desired sandwich or integrally stiffened structure. According to such method, a suitable mask is applied to selected areas of the aluminum or aluminum alloy blanks. The assembly is then placed in a vacuum chamber and at a suitable low pressure and suitable voltage a glow discharge is created between the metal blank or blanks functioning as cathode or sputtering target, and an anode to selectively remove the oxide from the metal blanks and deposit the oxide debris on the anode. After the oxide layers have been removed from the surfaces of the blanks to be bonded, such surfaces are brought into intimate contact within the sputtering chamber or in an area equipped with heated platens, and while preventing reoxidation of the cleaned surface areas of the metal blanks, such blanks are subjected to press pressure and heat. The cleaned oxide-free areas bond, while the remaining areas, protected by the natural oxide and covered by the masks, do not bond.

US Patent:

43064361, Dec 22, 1981

Filed:

May 12, 1980

Appl. No.:

6/148873

Inventors:

David W. Schulz - Hermosa Beach CA
Edward D. Weisert - Rolling Hills Estates CA

Assignee:

Rockwell International Corporation - El Segundo CA

International Classification:

B21B 3708

US Classification:

72 21

Abstract:

An improvement to an apparatus for and method of making structures from at least one workpiece is disclosed. The prior art apparatus and method comprised a pair of dies which were clamped about the periphery of the at least one workpiece creating a gap therebetween. A pair of non-inflatable platens were then used to apply a force against the pair of dies further clamping the workpiece in place. The die assembly and workpiece were then heated to forming temperatures and thereafter the workpiece was formed within the pair of dies by fluid under pressure. Typically the forming was Superplastic Forming or Superplastic Forming/Diffusion Bonding. The improvement to the apparatus and method comprises producing an inflatable platen mounted between one of the dies and one of the non-inflatable platens, adapted to regulate the force applied by said pair of dies to said at least one workpiece. A sensor is provided mounted within the gap adapted to sense changes in the dimensions of the actual gap and provide a first output signal proportional thereto during the forming of the structure. A signal generator is provided for producing a second output signal proportional to a preferred gap dimension that is produced when said force is the minimum amount necessary for forming the at least one workpiece into the structure.

US Patent:

43312845, May 25, 1982

Filed:

Mar 14, 1980

Appl. No.:

6/130505

Inventors:

David W. Schulz - Hermosa Beach CA
Vene L. Darby - Redondo Beach CA

Assignee:

Rockwell International Corporation - El Segundo CA

International Classification:

B23K 2014
B23K 2022

US Classification:

228157

Abstract:

An improvement is disclosed to the method of making metallic structures from a plurality of stacked workpieces or blanks by joining first portions, preferably by diffusion bonding, of the stack and by clamping the joined stack at its periphery between forming members and superplastically forming second portions of said plurality of stacked blanks by the selective application of fluid under pressure. The improvement is a method of coupling the fluid to the second portions of the stack which comprises providing a first port through one of the outer blanks at the periphery of the stack. At least one stopoff path is provided for coupling the first port to the second portions of the stacked blanks, which are to be superplastically formed. A second port is provided in one of the forming members, which couples the first port to a source of pressurized fluid. Where there are at least three blanks in the stack, a slot is provided within the inner blank or blanks of the stack coupling the first port to the at least one stopoff path.

US Patent:

45263124, Jul 2, 1985

Filed:

Dec 10, 1979

Appl. No.:

6/102091

Inventors:

Joseph R. Goss - Huntington Beach CA
David W. Schulz - Hermosa Beach CA

Assignee:

Rockwell International Corporation - El Segundo CA

International Classification:

B23K 3102

US Classification:

228157

Abstract:

A method of making metallic sandwich structures is disclosed using a plurality of metal blank workpieces with at least one of the blank workpieces capable of being superplastically formed against a surface of a die. At least one of the blanks is treated at selective areas to prevent bonding in those areas. The blanks are positioned in a stack with at least one of the outer workpieces of the stack having the capacity to be superplastically formed. The stack is then diffusion bonded together in the untreated areas. At least one insert, preferably made from wax, is coupled to the bonded stack such that the external configuration of the at least one insert and bonded stack conform to the external configuration of the sandwich structure. A mold is cast around the at least one insert and bonded stack, after which the at least one insert is removed from the mold. Thereafter, the bonded stack is superplastically formed within the cast mold, resulting in the desired sandwich structure.