Sutton Core SPF/DB Process In a Production Environment

The Sutton Core Process is a patented superplastic forming and diffusion bonding (SPF/DB) process that produces hollow titanium parts with rigid preformed cores made of reinforcing grids or honeycomb patterns sandwiched between superplastically formed cover sheets. The four main fabrication steps are described and several advantages of the process over other methods are discussed. The process has produced parts that have met stringent quality requirements including high structural integrity as seen from bird strike tests of prototype hollow fan blades. Key enablers such as final inflation and evacuation schedule, proper die design, temperature and pressure control and pre-cleaning and contamination prevention that helped transform it from a development process into a viable production process are also discussed. Special acknowledgement to Larry Leyrer and Kevin VanDyke, Barnes Aerospace, Lansing Division, Lansing, MI.