Daniel Alan Sanders

US Patent:

6430812, Aug 13, 2002

Filed:

Aug 28, 1998

Appl. No.:

09/141499

Inventors:

Daniel G. Sanders - Sumner WA

Assignee:

The Boeing Company - Seattle WA

International Classification:

B21D 5116

US Classification:

29890148, 7237004

Abstract:

A tubular part having a tubular main body and an integral tubular protrusion projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material. Linear actuators are operated to pull the rod and attached pull die through the hole at a predetermined rate which produces about an optimal superplastic strain rate for the material, thereby superplastically stretching marginal portions of the tubular body around the hole and forming the tubing material in marginal regions around the hole against surfaces defining the opening in the die base into the tubular protrusion integrally joined to the tube around an integral junction region.

US Patent:

6612020, Sep 2, 2003

Filed:

May 29, 2002

Appl. No.:

10/158022

Inventors:

Daniel G. Sanders - Sumner WA

Assignee:

The Boeing Company - Seattle MA

International Classification:

B23P 2100

US Classification:

29715, 29714, 29507, 29890148

Abstract:

A tubular part having a tubular main body and an integral tubular pullout projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material. Linear actuators are operated to pull the rod and attached pull die through the hole at a predetermined rate which produces about an optimal superplastic strain rate for the material, thereby superplastically stretching marginal portions of the tubular body around the hole and forming the tubing material in marginal regions around the hole against surfaces defining the opening in the die base into the tubular pullout integrally joined to the tube around an integral junction region.

US Patent:

6692844, Feb 17, 2004

Filed:

Aug 28, 2001

Appl. No.:

09/942162

Inventors:

Daniel G. Sanders - Sumner WA
Martin A. Peterson - Puyallup WA
David C. Van Aken - Rolla MO
D. Trent Weaver - Rolla MO
F. Scott Miller - Rolla MO
Jeffrey D. Smith - Rolla MO

Assignee:

The Boeing Company - Seattle WA

International Classification:

B01J 1718

US Classification:

428689, 428699, 428701, 428702, 428410, 428384, 428386, 428428, 42725513, 42725536, 427452, 427456, 761071

Abstract:

The life of ceramic SPF dies can be enhanced significantly by plasma spray application of a cordierite glaze on the forming surface. The preferred glaze has a coefficient of thermal expansion close to or matching with the ceramic of the die, and, typically, is a 2â2â5 MAS system including 2-10 mol % TiO (or above 8 wt %).

US Patent:

6820796, Nov 23, 2004

Filed:

Jul 17, 2002

Appl. No.:

10/199759

Inventors:

Daniel G. Sanders - Sumner WA

Assignee:

The Boeing Company - Chicago IL

International Classification:

B23K 2800

US Classification:

228157, 228193

Abstract:

A multisheet structure is made using compression diffusion bonding according to the present invention using a CRES template to apply increased pressure in the areas designated for diffusion bonds (DB) to improve the bond quality and to reduce the processing time. The CRES template is patterned to correspond with the DB arrangement in the superplastically formed part. The forming press forces the template against the pack of SPF sheets to provide 300-1200 psi or more pressure along the bond lines to speed their formation.

US Patent:

6832885, Dec 21, 2004

Filed:

Sep 4, 2002

Appl. No.:

10/234992

Inventors:

Daniel G. Sanders - Sumner WA
Mark T. Schergen - Mercer Island WA

Assignee:

The Boeing Company - Chicago IL

International Classification:

B66C 2300

US Classification:

4147446, 19875011, 294115

Abstract:

There is provided an apparatus for handling a structural member. The apparatus includes a beam that extends from a first end to a second end and a shuttle in translational communication with the beam in a direction extending between the first and second ends. A fork actuator is connected to the shuttle and capable of hydraulically raising and lowering a fork. The fork can include a cooling system to maintain a temperature of the fork, even when used in a heated environment.

US Patent:

6860517, Mar 1, 2005

Filed:

May 29, 2002

Appl. No.:

10/158029

Inventors:

Daniel G. Sanders - Sumner WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

F16L041/00

US Classification:

28513311, 2851333, 29890148

Abstract:

A tubular part having a tubular main body and an integral tubular pullout projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material. Linear actuators are operated to pull the rod and attached pull die through the hole at a predetermined rate which produces about an optimal superplastic strain rate for the material, thereby superplastically stretching marginal portions of the tubular body around the hole and forming the tubing material in marginal regions around the hole against surfaces defining the opening in the die base into the tubular pullout integrally joined to the tube around an integral junction region.

US Patent:

7210611, May 1, 2007

Filed:

Oct 21, 2004

Appl. No.:

10/970151

Inventors:

Daniel G. Sanders - Sumner WA, US
David W. Foutch - Seattle WA, US
Jeff D. Will - Renton WA, US
Luis Leon - Federal Way WA, US
Gregory L. Ramsey - Seabeck WA, US
Garry A. Booker - Lake Stevens WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B23K 31/02

US Classification:

2281121, 228 21, 244117 R, 72 61

Abstract:

A superplastically formed structural assembly is provided, as is an associated preform and method for forming such an assembly. The assembly includes a skin member and a support member that are joined to define a space between the members and between the joints. The assembly can be produced by joining the members in a flat configuration, and then forming the resulting preform to a predetermined shape of the structural assembly. The support member defines at least one aperture in communication with the space between the members. Thus, the skin member can be formed by delivering a pressurized fluid through the support member to the skin member, e. g. , to superplastically form the skin member against a die that defines a contour surface corresponding in shape to the predetermined configuration of the assembly. The support member can extend in a substantially direct configuration between opposing portions of the skin member.

US Patent:

7967240, Jun 28, 2011

Filed:

Mar 16, 2007

Appl. No.:

11/687244

Inventors:

Daniel G. Sanders - Sumner WA, US
David W. Foutch - Seattle WA, US
Jeff D. Will - Renton WA, US
Luis Leon - Federal Way WA, US
Gregory L. Ramsey - Seabeck WA, US
Garry A. Booker - Lake Stevens WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B64D 33/02

US Classification:

244 53B, 123 417

Abstract:

A superplastically formed structural assembly is provided, as is an associated preform and method for forming such an assembly. The assembly includes a skin member and a support member that are joined to define a space between the members and between the joints. The assembly can be produced by joining the members in a flat configuration, and then forming the resulting preform to a predetermined shape of the structural assembly. The support member defines at least one aperture in communication with the space between the members. Thus, the skin member can be formed by delivering a pressurized fluid through the support member to the skin member, e. g. , to superplastically form the skin member against a die that defines a contour surface corresponding in shape to the predetermined configuration of the assembly. The support member can extend in a substantially direct configuration between opposing portions of the skin member.