D. G. Sanders, L. D. Hefti, The Boeing Company, Seattle, WA
Superplastic Forming (SPF) was developed concurrently in several different divisions in what has now been consolidated into the Boeing Company. The evolution from pure scientific research through to the current state-of-the-art in automation and mass production are explored.
The North American Rockwell organization, along with their subsidiary, the Rockwell Science Center, performed pioneering work in the development of SPF of titanium and later made historical innovations in Diffusion Bonding (DB), which they combined together to create the Superplastic Forming and Diffusion Bonding process (SPF/DB). This organization was granted close to 100 U.S. patents during the 1970’s through the end of the 1980’s. The application of these methods was targeted primarily on the B1B airplane.
The McDonnell Douglas organization found alternative ways to combine welding technologies with SPF and DB in order to fabricate complex sandwich structure using less press time than was required for the Rockwell methods. The 2-sheet SPF/DB and 4-sheet SPF/DB integrally stiffened panels were used extensively on the F-15E aircraft and several other aero-structures. The major developments for these manufacturing processes occurred during the 1970’s through 1990’s.
The Boeing Puget Sound organization developed a primitive SPF process during the late 1960’s and early 1970’s, but then abandoned the process for nearly 20 years. In 1988, a new R&D initiative was undertaken geared towards mass production of both aluminum and titanium parts. A manufacturing center for SPF and SPF/DB was subsequently setup for both military and commercial applications. Many medium to large sized assemblies that had been previously been fabricated in multiple pieces were converted to monolithic structures for cost and weight savings.
Summary: Superplastic Forming (SPF) was developed concurrently in several different divisions in what has now been consolidated into the Boeing Company. The evolution from pure scientific research through to the current state-of-the-art in automation and mass production are explored.
The North American Rockwell organization, along with their subsidiary, the Rockwell Science Center, performed pioneering work in the development of SPF of titanium and later made historical innovations in Diffusion Bonding (DB), which they combined together to create the Superplastic Forming and Diffusion Bonding process (SPF/DB). This organization was granted close to 100 U.S. patents during the 1970’s through the end of the 1980’s. The application of these methods was targeted primarily on the B1B airplane.
The McDonnell Douglas organization found alternative ways to combine welding technologies with SPF and DB in order to fabricate complex sandwich structure using less press time than was required for the Rockwell methods. The 2-sheet SPF/DB and 4-sheet SPF/DB integrally stiffened panels were used extensively on the F-15E aircraft and several other aero-structures. The major developments for these manufacturing processes occurred during the 1970’s through 1990’s.
The Boeing Puget Sound organization developed a primitive SPF process during the late 1960’s and early 1970’s, but then abandoned the process for nearly 20 years. In 1988, a new R&D initiative was undertaken geared towards mass production of both aluminum and titanium parts. A manufacturing center for SPF and SPF/DB was subsequently setup for both military and commercial applications. Many medium to large sized assemblies that had been previously been fabricated in multiple pieces were converted to monolithic structures for cost and weight savings.
