Methods for producing creep age formed aircraft components

Abstract

Aircraft components are produced by creep age forming (CAF) processes whereby a flat plate is initially subjected to CAF processing to produce a curved product preform which is thereafter machined to remove material therefrom so as to produce the final aircraft component.

What is claimed is: 
     
         1 . A process for producing an aircraft component having integral structural features which comprises the sequential steps of:
 (a) providing a flat plate;   (b) placing the flat plate on a forming tool defining a curved surface which approximates a final curved shape of the aircraft component;   (c) subjecting the flat plate on the forming tool to creep age forming in an autoclave to produce a curved component preform thereof; and thereafter   (d) machining the curved component preform to form the integral features and thereby produce the aircraft component.   
     
     
         2 . The process according to  claim 1 , wherein step (c) comprises subjecting the flat plate to autoclave conditions for a time sufficient to allow the flat plate to assume the approximate final curved shape of the aircraft component. 
     
     
         3 . The process according to  claim 1 , wherein step (a) comprises providing a flat plate that has perimetrical dimension that is identical to the aircraft component, and a thickness dimension that is at least equal to a thickest portion of the aircraft component. 
     
     
         4 . The process according to  claim 3 , wherein the thickness of the flat plate is substantially constant. 
     
     
         5 . The process according to  claim 3 , wherein step (d) is practiced so as to mill the curved component preform to remove material thereof and form the integral features of the aircraft component. 
     
     
         6 . The process according to  claim 1 , wherein step (c) comprises placing the flat plate within a vacuum forming bag. 
     
     
         7 . The process according to  claim 1 , wherein the integral features includes at least one selected from the group consisting of stiffeners, pads, pockets and openings.