High velocity forming of local features using a projectile

Abstract

A system and method for accomplishing localized feature forming in a sheet of material and/or the localized joining of multiple sheets of material. The system and method may also be used to attach a secondary component to a sheet of material. The system and method of the present invention employs a die having a shaped cavity for receiving a portion of the sheet material. A projectile is propelled from a projectile firing device to impact the sheet or sheets of material in the area overlying the subjacent die cavity. The projectile forces a portion of the sheet material into the die cavity, imparting a shape thereto. The kinetic energy transferred from the projectile to the sheet material may be used to form a metallurgical bond between multiple sheets of material. The metallurgical bond can be used alone to join the sheets, or may be used in conjunction with an interlocking shape to provide extra strength.

1 . A system for attaching a secondary component to a metallic sheet, comprising: 
 a die having a cavity for imparting a shaped feature to said metallic sheet, said die adapted to reside near said metallic sheet such that said cavity lies subjacent thereto;    a secondary component for attachment to said metallic sheet, said secondary component having an aperture adapted to receive a portion of said metallic sheet, wherein said secondary component is releasably secured within said cavity of said die prior to attachment of said secondary component to said metallic sheet; and    a projectile firing device in substantial alignment with said cavity, said projectile firing device for propelling a projectile at a high velocity into said metallic sheet, wherein said projectile is adapted to be propelled from said projectile firing device into said metallic sheet at a point that is in substantial alignment with said aperture in said secondary component so as to cause at least a portion of said metallic sheet to be forced through said aperture in said secondary component and so as to subsequently cause said portion of said metallic sheet forced through said aperture to expand outwardly upon contact with said die cavity, said expansion continuing beyond the circumference of said aperture.    
   
   
       2 . The system for attaching a secondary component to a metallic sheet according to  claim 1  wherein said secondary component is releasably secured within said cavity by a vacuum.  
   
   
       3 . The system for attaching a secondary component to a metallic sheet according to  claim 1  wherein said secondary component is releasably secured within said cavity by a magnet.  
   
   
       4 . The system for attaching a secondary component to a metallic sheet according to  claim 1  wherein said secondary component is releasably secured within said cavity by mechanical means.  
   
   
       5 . The system for attaching a secondary component to a metallic sheet according to  claim 1  wherein said projectile is metal.  
   
   
       6 . The system for attaching a secondary component to a metallic sheet according to  claim 1  wherein said projectile is plastic.  
   
   
       7 . The system for attaching a secondary component to a metallic sheet according to  claim 1  wherein said projectile is a liquid.  
   
   
       8 . The system for attaching a secondary component to a metallic sheet according to  claim 1  wherein said projectile is ice.  
   
   
       9 . A system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, comprising: 
 a secondary component having a receiving shape;    at least one metallic sheet placed over said receiving shape; and    a projectile firing device in substantial alignment with said receiving shape, said projectile firing device for propelling a projectile at a high velocity into said at least one metallic sheet, wherein said projectile is adapted to be propelled from said projectile firing device into said one or more metallic sheets so as to cause at least a portion of said one or more metallic sheets to be forced into said receiving shape.    
   
   
       10 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 9 , wherein said at least one metallic sheet remains attached to said secondary component by means of an interlocking joint formed therebetween.  
   
   
       11 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 9 , wherein said one or more metallic sheets remain attached to said secondary component by means of a metallurgical bond formed between said one or more metallic sheets and said secondary component.  
   
   
       12 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 9 , wherein said at least one metallic sheet remains attached to said secondary component by a combination of an interlocking joint and a metallurgical bond formed between said at least one metallic sheet and said secondary component.  
   
   
       13 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 9 , further comprising a means for securing the position of said at least one metallic sheet prior to the firing of said projectile.  
   
   
       14 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 13 , wherein said means for securing the position of said at least one metallic sheet prior to the firing of said projectile is a vacuum.  
   
   
       15 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 13 , wherein said means for securing the position of said at least one metallic sheet prior to the firing of said projectile is a magnet.  
   
   
       16 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 13 , wherein said means for securing the position of said at least one metallic sheet prior to the firing of said projectile is mechanical.  
   
   
       17 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 9 , wherein said projectile is metal.  
   
   
       18 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 9 , wherein said projectile is plastic.  
   
   
       19 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 9 , wherein said projectile is a liquid.  
   
   
       20 . The system for attaching a secondary component to at least one metallic sheet, wherein said component has substantially more mass than said at least one metallic sheet, according to  claim 9 , wherein said projectile is ice.