David P Schulz

US Patent:

59882255, Nov 23, 1999

Filed:

Jun 6, 1995

Appl. No.:

8/469305

Inventors:

David W. Schulz - Kent WA

Assignee:

The Boeing Company - Seattle WA

International Classification:

F16L 900

US Classification:

138109

Abstract:

A tubular part formed by superplastic forming has a tubular structure made of superplastic material having a tubular wall with an outside surface like an inside surface of a die against which the tubular wall was superplastically formed by heating to superplastic forming temperature, and injecting the forming gas through connectors in end portions of the tubular structure, sealed against escape of forming gas from the tubular structure, to inflate the tubular structure against the inside surface of the die. Two open ends at opposite ends of the tubular wall are made by cutting off the end portions of the tubular structure. An integral projecting pull-out in the tubular wall for connection to a connecting tube is formed simultaneously with the tubular wall against a concave shape on the die.

US Patent:

60819820, Jul 4, 2000

Filed:

Mar 15, 1996

Appl. No.:

8/616787

Inventors:

David W. Schulz - Kent WA

Assignee:

The Boeing Company - Seattle WA

International Classification:

B21D 2602

US Classification:

294211

Abstract:

A process for superplastically forming a tube of superplastic material to make a part includes sealing both ends of the tube with end caps to provide a sealed enclosed volume within the tube. At least one of the end caps has a connection that communicates between the enclosed volume and a gas line for connection to a gas management system for controlling forming gas pressure inside the enclosed space. The tube is inserting in a die and the connection is coupled to a gas supply line from said gas management system for supplying forming gas under pressure to said enclosed volume. The die and the tube are heated to the superplastic forming temperature for said material, and gas is introduced from the gas management system for pressurizing the enclosed volume with pressurized forming gas and for expanding the tube against the internal surfaces of the die. After forming the tube, the pressurized forming gas is vented from the enclosed volume, the expanded tube is cooled, and the expanded tube is removed from the die. Finally, the end portions of the tube, including the end caps, are removed from the tube.

US Patent:

56494394, Jul 22, 1997

Filed:

Jun 6, 1995

Appl. No.:

8/469304

Inventors:

David W. Schulz - Kent WA

Assignee:

The Boeing Co. - Seattle WA

International Classification:

B21D 2602

US Classification:

72 62

Abstract:

A tool for sealing two ends of a tube of superplastic material in preparation for superplastically forming the tube against inside surfaces of a die by gas pressure inside of the tube. The tool has a longitudinal axis that is coincident with the longitudinal axis of the tube when the tool is positioned in the tube, and has two end caps with a cross-sectional shape similar to the cross-sectional shape of the tube ends on a plane perpendicular to the axis. A central connecting tube extends between and connects the two end caps. The end caps are made of a material having a coefficient of thermal expansion that is greater than the coefficient of thermal expansion of the tube, and expand, on heating, into intimate sealing contact with the inside surface of the tube ends. A gas connector in at least one of the end caps, located in the end cap radially outside the connection of the connecting tube to the end cap, connects a gas line from a gas management system for introducing forming gas under pressure into the tube, after the ends thereof are sealed by the end caps and the tube is heated to the thermoplastic forming temperature thereof, for inflating the tube against the inside surfaces of the die. The gas needs to fill and act only in the volume between the connecting tube and the tube instead of the entire volume of the tube, thereby saving forming gas.

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.