Tool for heating and quenching a structure

A structure is heated in a tool. The structure is quenched in the tool such that a shape of the structure is maintained, in which quenching is performed by contacting the structure with a quenching medium.

BACKGROUND INFORMATION

The present disclosure relates generally to heat treating structures and, more specifically, to heating and quenching structures in the same tool.

Structures are heat treated to achieve desired material characteristics. After heating a structure, the structure is subjected to a controlled cooling.

One type of controlled cooling is quenching. Quenching is a rapid cooling of the structure. Maintaining dimensional tolerances following heat treatment is difficult due to warping during quenching.

In some processes, to create a structure having a desired shape, heat treatment is avoided after forming the desired shape. If heat treatment is not performed, the structure may not have the desired material characteristics.

In some processes, a structure having excess material is heated and quenched. After quenching, the excess material is removed to form a desired shape for the structure. The material removal adds at least one of manufacturing time, manufacturing waste, or cost to the structure.

Therefore, it would be desirable to have a method and apparatus that take into account at least some of the issues discussed above, as well as other possible issues. For example, it would be desirable to have a method and apparatus to perform quenching without warping. As another example, it would be desirable to reduce at least one of manufacturing time or material waste produced to form a part having desired final dimensions after heating and quenching.

SUMMARY

An illustrative embodiment of the present disclosure provides a method. A structure is heated in a tool. The structure is quenched in the tool such that a shape of the structure is maintained, in which quenching is performed by contacting the structure with a quenching medium.

Another illustrative embodiment of the present disclosure provides a tooling die. The tooling die comprises a plurality of dielectric laminates, a ceramic facing, a contoured smart susceptor, and induction coils. The plurality of dielectric laminates has air gaps defined between adjacent dielectric laminates. The ceramic facing is connected to at least some of the plurality of dielectric laminates. The contoured smart susceptor contacts the ceramic facing. The contoured smart susceptor has a curve in a first cross-sectional direction. The induction coils are disposed in some of the air gaps formed between adjacent dielectric laminates, wherein each induction coil of the induction coils extends through a single air gap.

A further illustrative embodiment of the present disclosure provides an induction tool. The induction tool comprises a first tooling die and a second tooling die movable relative to each other, each of the first tooling die and the second tooling die having a respective contoured smart susceptor having apertures.

A yet further illustrative embodiment of the present disclosure provides a method. A plurality of dielectric laminates is positioned such that air gaps are defined between adjacent laminates. A ceramic facing is connected to at least some of the plurality of dielectric laminates. Induction coils are disposed in some of the air gaps formed between adjacent dielectric laminates, wherein each induction coil of the induction coils extends through a single air gap. A contoured smart susceptor is placed in contact with the ceramic facing to form a first tooling die, the contoured smart susceptor having a curve in a first cross-sectional direction.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that aluminum lip skins for aircraft have complex curvatures. The illustrative embodiments recognize and take into account that aluminum lip skins for aircraft desirably undergo heat treatment to produce desired material characteristics. For example, the illustrative embodiments recognize and take into account that, for aircraft components, it is desirable to establish a solution treated condition in an aluminum aircraft component. The illustrative embodiments recognize and take into account that the aluminum alloy component would be heated to the solution treatment temperature and then cooled rapidly. The illustrative embodiments recognize and take into account that it is desirable for a quench speed to be sufficient to produce the needed W condition. The illustrative embodiments recognize and take into account that in some instances, a quenched component will be aged to provide desired mechanical attributes. The illustrative embodiments recognize and take into account that maintaining dimensional tolerances of the aluminum lip skins during heat treatment is undesirably difficult due to warping during quenching.

The illustrative embodiments recognize and take into account that it is desirable to maintain dimensional control of a structure after heating and quenching the structure. For example, the illustrative embodiments recognize and take into account that it is desirable for an aluminum lip skin type structure to be solution treated and quenched with dimensional control of the structure.

The illustrative embodiments recognize and take into account that it is desirable to have as little forming and shaping work as possible for a part after heat treatment. The illustrative embodiments recognize and take into account that it is desirable to heat and quench a part having dimensions as close as possible to the desired final dimensions. The illustrative embodiments recognize and take into account that heating and quenching parts having dimensions as close as possible to final dimensions desirably reduces manufacturing time after heating and quenching.

Referring now to the figures and, in particular, with reference toFIG. 1, an illustration of a block diagram of a manufacturing environment in which a structure is heated and quenched in a tool is depicted in accordance with an illustrative embodiment. Structure100receives heating102and quenching104in manufacturing environment105. Tool106performs heating102and quenching104on structure100. Quenching104structure100in induction tool108is performed such that shape109of the structure100is maintained.

As depicted, tool106is induction tool108. Induction tool108comprises first tooling die110and second tooling die112movable relative to each other. Each of first tooling die110and second tooling die112have a respective contoured smart susceptor having apertures. As used herein, a smart susceptor is constructed of a material, or materials, that generate heat efficiently until reaching a threshold (i.e., Curie) temperature. First tooling die110has contoured smart susceptor114with apertures116. Second tooling die112has contoured smart susceptor118with apertures120.

Induction tool108further comprises quenching system122in communication with the apertures of each respective contoured smart susceptor. Quenching system122is in communication with apertures116of contoured smart susceptor114. Quenching system122is in communication with apertures120of contoured smart susceptor118.

Induction tool108further comprises induction coils disposed between first plurality of dielectric laminates124of first tooling die110and second plurality of dielectric laminates126of second tooling die112. Induction coils128are disposed between first plurality of dielectric laminates124. Induction coils130are disposed between second plurality of dielectric laminates126.

In some illustrative examples, each respective contoured smart susceptor has an expansion joint. As depicted, contoured smart susceptor114has expansion joint132. As depicted, contoured smart susceptor118has expansion joint134.

Expansion joint132allows for contoured smart susceptor114to expand during heat-up. Expansion joint132absorbs thermal expansion of contoured smart susceptor114. In some illustrative examples, expansion joint132is a circumferential discontinuity in contoured smart susceptor114.

Expansion joint134allows for contoured smart susceptor118to expand during heat-up. Expansion joint134absorbs thermal expansion of contoured smart susceptor118. In some illustrative examples, expansion joint134is a circumferential discontinuity in contoured smart susceptor118.

Although only one expansion joint is depicted in each of contoured smart susceptor114and contoured smart susceptor118, any desirable quantity of expansion joints may be present. In some illustrative examples, contoured smart susceptor114and contoured smart susceptor118each have two or more expansion joints.

First tooling die110comprises first plurality of dielectric laminates124, ceramic facing136, contoured smart susceptor114, and induction coils128. First plurality of dielectric laminates124have first air gaps138defined between adjacent dielectric laminates. Ceramic facing136is connected to at least some of first plurality of dielectric laminates124. Contoured smart susceptor114contacts ceramic facing136. Ceramic facing136is formed from one or more ceramic portions. Ceramic facing136may have any desirable design configured to protect first plurality of dielectric laminates124from convective or conductive heat. Ceramic facing136may have any desirable design configured to allow flow of quenching medium146to apertures116.

In some illustrative examples, ceramic facing136is a single ceramic portion. In other illustrative examples, ceramic facing136has the same quantity of ceramic portions as a quantity of dielectric laminates in first plurality of dielectric laminates124. In these illustrative examples, each ceramic portion of ceramic facing136would be associated with a dielectric laminate of first plurality of dielectric laminates124. In some illustrative examples, ceramic facing136has a quantity of ceramic portions less than a quantity of dielectric laminates in first plurality of dielectric laminates124, such that some ceramic portions are connected to more than one dielectric laminates in first plurality of dielectric laminates124.

Contoured smart susceptor114has curve140in first cross-sectional direction142. Induction coils128are disposed in some of first air gaps138formed between adjacent dielectric laminates. Each induction coil of induction coils128extends through a single air gap. In some illustrative examples, each of first air gaps138has a respective induction coil of induction coils128. In other illustrative examples, at least one air gap of first air gaps138does not have an induction coil. In some illustrative examples, induction coils128run substantially parallel to curve140of contoured smart susceptor114in first cross-sectional direction142.

In some illustrative examples, conduits144of quenching system122are disposed in some of first air gaps138. In some illustrative examples, quenching system122has conduits144extending along induction coils128.

First plurality of dielectric laminates124is laid out in any desirable layout. In some illustrative examples, each of first plurality of dielectric laminates124run substantially parallel to each other. In some illustrative examples, each of first plurality of dielectric laminates124are arranged in a fan shape relative to a centerline of first tooling die110.

First tooling die110also comprises plurality of bridging strips150within ceramic facing136. Plurality of bridging strips150provides support to contoured smart susceptor114. Plurality of bridging strips150contacts contoured smart susceptor114. In some illustrative examples, plurality of bridging strips150is formed of metallic laminates152.

In some illustrative examples, plurality of bridging strips150run substantially perpendicular to first plurality of dielectric laminates124. Each of plurality of bridging strips150extend over multiple air gaps of first air gaps138.

In some illustrative examples, plurality of bridging strips150is parallel to each other. In some illustrative examples, plurality of bridging strips150is positioned between induction coils128and contoured smart susceptor114.

Plurality of bridging strips150does not contact first plurality of dielectric laminates124. Ceramic facing136is positioned between first plurality of dielectric laminates124and plurality of bridging strips150. Ceramic facing136protects first plurality of dielectric laminates124from conductive heating. First plurality of dielectric laminates124is formed of a material that is not inductively heated by induction coils128.

Second tooling die112comprises second plurality of dielectric laminates126, ceramic facing154, contoured smart susceptor118, and induction coils130. Second plurality of dielectric laminates126have second air gaps156defined between adjacent dielectric laminates. Ceramic facing154is connected to at least some of second plurality of dielectric laminates126. Contoured smart susceptor118contacts ceramic facing154. Ceramic facing154is formed from one or more ceramic portions. Ceramic facing154may have any desirable design configured to protect second plurality of dielectric laminates126from convective or conductive heat. Ceramic facing154may have any desirable design configured to allow flow of quenching medium146to apertures120.

In some illustrative examples, ceramic facing154is a single ceramic portion. In other illustrative examples, ceramic facing154has the same quantity of ceramic portions as a quantity of dielectric laminates in second plurality of dielectric laminates126. In these illustrative examples, each ceramic portion of ceramic facing154would be associated with a dielectric laminate of second plurality of dielectric laminates126. In some illustrative examples, ceramic facing154has a quantity of ceramic portions less than a quantity of dielectric laminates in second plurality of dielectric laminates126, such that some ceramic portions are connected to more than one dielectric laminates in second plurality of dielectric laminates126.

Contoured smart susceptor118has curve158in first cross-sectional direction142. Induction coils130are disposed in some of second air gaps156formed between adjacent dielectric laminates. Each induction coil of induction coils130extends through a single air gap. In some illustrative examples, each of second air gaps156has a respective induction coil of induction coils130. In other illustrative examples, at least one air gap of second air gaps156does not have an induction coil. In some illustrative examples, induction coils130run substantially parallel to curve158of contoured smart susceptor118in first cross-sectional direction142.

In some illustrative examples, conduits160of quenching system122are disposed in some of second air gaps156. In some illustrative examples, quenching system122has conduits160extending along induction coils130.

Second plurality of dielectric laminates126is laid out in any desirable layout. In some illustrative examples, each of second plurality of dielectric laminates126run substantially parallel to each other. In some illustrative examples, each of second plurality of dielectric laminates126are arranged in a fan shape relative to a centerline of second tooling die112.

Second tooling die112also comprises plurality of bridging strips162within ceramic facing154. Plurality of bridging strips162provides support to contoured smart susceptor118. Plurality of bridging strips162contacts contoured smart susceptor118. In some illustrative examples, plurality of bridging strips162is formed of metallic laminates164.

In some illustrative examples, plurality of bridging strips162run substantially perpendicular to second plurality of dielectric laminates126. Each of plurality of bridging strips162extend over multiple air gaps of second air gaps156.

In some illustrative examples, plurality of bridging strips162is parallel to each other. In some illustrative examples, plurality of bridging strips162is positioned between induction coils130and contoured smart susceptor118.

Plurality of bridging strips162does not contact second plurality of dielectric laminates126. Ceramic facing154is positioned between second plurality of dielectric laminates126and plurality of bridging strips162. Ceramic facing154protects second plurality of dielectric laminates126from conductive heating. Second plurality of dielectric laminates126is formed of a material that is not inductively heated by induction coils130.

First tooling die110is connected to support166. Support166provides a foundation for first plurality of dielectric laminates124. Second tooling die112is connected to support168. Support168provides a foundation for second plurality of dielectric laminates126.

First tooling die110and second tooling die112close together to form tool cavity170. Tool cavity170contains structure100for heating102and quenching104. First tooling die110and second tooling die112restrain structure100within tool cavity170. Complex contour172of structure100is the same as a shape of tool cavity170. Shape109of structure100includes complex contour172.

Turning now toFIG. 2, an illustration of an isometric view of a tooling die is depicted in accordance with an illustrative embodiment. Tooling die200is a physical implementation of one of first tooling die110or second tooling die112ofFIG. 1.

Tooling die200comprises plurality of dielectric laminates202, ceramic facing204, contoured smart susceptor206, and induction coils208. Plurality of dielectric laminates202have air gaps210defined between adjacent dielectric laminates. For example, air gap212is defined between adjacent dielectric laminates, dielectric laminate214and dielectric laminate216. As depicted, each of plurality of dielectric laminates202is arranged in fan shape217relative to centerline219of tooling die200.

Ceramic facing204is connected to at least some of plurality of dielectric laminates202. Contoured smart susceptor206contacts ceramic facing204. Contoured smart susceptor206has curve218in first cross-sectional direction220.

Induction coils208are disposed in some of air gaps210formed between adjacent dielectric laminates. For example, induction coil221is disposed in air gap212between adjacent dielectric laminates, dielectric laminate214and dielectric laminate216. Each induction coil of induction coils208extends through a single air gap. For example, induction coil221extends through only air gap212.

As depicted, each of air gaps210has a respective induction coil of induction coils208. As depicted, only one induction coil of induction coils208is positioned in each air gap of air gaps210. In some non-depicted examples, some air gaps of air gaps210do not have induction coils. In some non-depicted examples, at least one air gap of air gaps210has more than one induction coil of induction coils208.

As depicted, contoured smart susceptor206has expansion joint222. Expansion joint222allows for contoured smart susceptor206to expand during heat-up. Expansion joint222absorbs thermal expansion of contoured smart susceptor206. As depicted, expansion joint222is a circumferential discontinuity in contoured smart susceptor206.

As depicted, tooling die200also includes support224. In some illustrative examples, support224may also be referred to as a base. Support224is formed of any desirable material. In some illustrative examples, support224is formed of a composite material. Support224of tooling die200provides a foundation for plurality of dielectric laminates202.

Turning now toFIG. 3, an illustration of a cross-sectional view of an induction tool and a structure is depicted in accordance with an illustrative embodiment. Induction tool300is a physical implementation of induction tool108ofFIG. 1. Induction tool300has first tooling die302and second tooling die304movable relative to each other. In some illustrative examples, second tooling die304is an implementation of tooling die200ofFIG. 2.

Each of first tooling die302and second tooling die304has a respective contoured smart susceptor having apertures. First tooling die302has contoured smart susceptor306. Second tooling die304has contoured smart susceptor308. Contoured smart susceptor306has apertures310. Contoured smart susceptor308has apertures312.

As depicted, ceramic facing314is positioned between dielectric laminate316of first tooling die302and contoured smart susceptor306. Ceramic facing314protects dielectric laminate316from heat generated by contoured smart susceptor306. As depicted, ceramic facing318is positioned between dielectric laminate320of second tooling die304and contoured smart susceptor308. Ceramic facing318protects dielectric laminate320from heat generated by contoured smart susceptor308.

A plurality of bridging strips313is positioned within ceramic facing314. A plurality of bridging strips315is positioned within ceramic facing318. In some illustrative examples, the plurality of bridging strips315is formed of metallic laminates.

In this cross-sectional view, plurality of bridging strips313in the form of metallic laminates322run substantially perpendicular to dielectric laminate316. As depicted, plurality of bridging strips313in the form of metallic laminates322run into and out of the page inFIG. 3while dielectric laminate316runs in plane with the page. In this cross-sectional view, the plurality of bridging strips315in the form of metallic laminates324, run substantially perpendicular to dielectric laminate320. As depicted, plurality of bridging strips315in the form of metallic laminates324run into and out of the page inFIG. 3while dielectric laminate320runs in plane with the page.

Induction coil326is disposed within air gap328. In this cross-sectional view, the plurality of bridging strips313in the form of metallic laminates322, is positioned between induction coil326and contoured smart susceptor306. Induction coil330is disposed within air gap332. In this cross-sectional view, the plurality of bridging strips315in the form of metallic laminates324, is positioned between induction coil330and contoured smart susceptor308.

As depicted, structure334is positioned on contoured smart susceptor306of first tooling die302. Structure334is a physical implementation of structure100ofFIG. 1. Structure334has shape336. Structure334will be heated and quenched in induction tool300. To close induction tool300, at least one of first tooling die302and second tooling die304is moved towards the other tooling die.

For example, “at least one of item A, item B, or item C” may include, without limitation, item A, item A and item B, or item B. This example also may include item A, item B, and item C, or item B and item C. Of course, any combination of these items may be present. In other examples, “at least one of” may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations.

Turning now toFIG. 4, an illustration of a cross-sectional view of an induction tool and a structure during heating is depicted in accordance with an illustrative embodiment. View400is a view of induction tool300and structure334after closing induction tool300. As depicted, structure334contacts contoured smart susceptor306and contoured smart susceptor308. Contoured smart susceptor306and contoured smart susceptor308hold structure334in place during heating and quenching. By holding structure334in place during heating and quenching, structure334retains shape336.

In some illustrative examples, view400is a view prior to heating of structure334. In some illustrative examples, view400is a view during heating of structure334.

During heating of structure334, induction coil326excites contoured smart susceptor306to heat contoured smart susceptor306. During heating of structure334, induction coil330excites contoured smart susceptor306to heat contoured smart susceptor308.

Ceramic facing314shields dielectric laminate316from convective heating from contoured smart susceptor306. The material of dielectric laminate316is selected to not inductively heat when exposed to a magnetic field from induction coil326. Ceramic facing318shields dielectric laminate320from convective and conductive heating from contoured smart susceptor308. The material of dielectric laminate320is selected to not inductively heat when exposed to a magnetic field from induction coil330.

Turning now toFIG. 5, an illustration of a cross-sectional view of an induction tool and a structure during quench is depicted in accordance with an illustrative embodiment. View500is a view of induction tool300and structure334during quench.

Quenching is performed in a short period of time. In some illustrative examples, quenching reduces the temperature of structure334to room temperature in under ten seconds.

Quenching system504of induction tool300has any desirable quantity of conduits. Further, quenching system504provides any desirable type of quenching medium.

Turning now toFIG. 6, an illustration of a cross-sectional view of an induction tool and a heat treated and quenched structure is depicted in accordance with an illustrative embodiment. View600is a view of induction tool300and structure334after heat treating and quenching of structure334in induction tool300. In view600, structure334has retained shape336despite having received heating and quenching.

Turning now toFIG. 7, an illustration of a top view of a tooling die with a contoured smart susceptor in phantom is depicted in accordance with an illustrative embodiment. Tooling die700is a physical implementation of one of first tooling die110or second tooling die112ofFIG. 1. View702is a view looking onto contoured smart susceptor704of tooling die700. In view702, contoured smart susceptor704is in phantom to view plurality of bridging strips706and ceramic facing708. Plurality of bridging strips706is within ceramic facing708. Dielectric laminates (not depicted) are protected from heat of contoured smart susceptor704by ceramic facing708. The dielectric laminates are obscured by ceramic facing708in view702.

In view702, induction coils and conduits are not depicted for ease of illustration and discussion purposes only. Any desirable quantity of induction coils and any desirable number of conduits may be present in view702. For example, each ofFIGS. 9 and 10may be implementations of a side view of tooling die700having different quantities of induction coils and conduits.

Plurality of bridging strips706is positioned between the induction coils (not depicted) and contoured smart susceptor704. Plurality of bridging strips706contacts contoured smart susceptor704. Plurality of bridging strips706is formed of metallic laminates710. As depicted, metallic laminates710support contoured smart susceptor704. In view702, metallic laminates710extend substantially perpendicular to ceramic facing708. As depicted, plurality of bridging strips706run substantially perpendicular to the dielectric laminates. As depicted, plurality of bridging strips706is parallel to each other.

In this illustrative example, each bridging strip of plurality of bridging strips706crosses over multiple dielectric laminates. For example, bridging strip714crosses over a dielectric laminate obscured by ceramic portion716of ceramic facing708and a dielectric laminate obscured by ceramic portion718of ceramic facing708. In this illustrative example, each bridging strip of plurality of bridging strips706extends over multiple air gaps. For example, bridging strip714crosses over air gap720and air gap722of air gaps724.

As depicted, contoured smart susceptor704has expansion joint712. Expansion joint712allows for contoured smart susceptor704to expand during heat-up. Expansion joint712absorbs thermal expansion of contoured smart susceptor704. In some illustrative examples, expansion joint712is a circumferential discontinuity in contoured smart susceptor704.

Turning now toFIG. 8, an illustration of a front view of a tooling die with dielectric laminate in phantom is depicted in accordance with an illustrative embodiment. View800is a front view of tooling die700ofFIG. 7.

Induction coil802and dielectric laminate804are visible in view800. As can be seen in view800, plurality of bridging strips706is positioned between induction coil802and contoured smart susceptor704. Plurality of bridging strips706contacts contoured smart susceptor704. Plurality of bridging strips706do not contact dielectric laminate804.

Also visible in view800is support806. Support806may also be referred to as a base. When present, support806is formed of any desirable material. In some illustrative examples, support806is formed of a composite material. When present, support806of tooling die700provides a foundation for dielectric laminate804and other dielectric laminates (not depicted) of tooling die700.

Turning now toFIG. 9, an illustration of a side view of a tooling die is depicted in accordance with an illustrative embodiment. In some illustrative examples, view900is a side view of tooling die700ofFIG. 7.

Induction coils901and conduits902run through air gaps904formed by adjacent dielectric laminates of plurality of dielectric laminates906. For example, induction coil908and conduit909run through air gap910of air gaps904. Air gap910is formed by adjacent dielectric laminates, dielectric laminate912and dielectric laminate914. As depicted, induction coils901are positioned in every other air gap of air gaps904. As depicted, induction coils901and conduits902run through the same air gaps of air gaps904. As depicted, only a single induction coil of induction coils901is positioned in a single air gap. For example, only induction coil908of induction coils901is present in air gap910of air gaps904.

Although view900is described as a side view of tooling die700, a side view of tooling die700may have alternative non-depicted embodiments. For examples, tooling die700may have any desirable quantity of induction coils901. In some non-depicted examples, induction coils901may run through additional air gaps of air gaps904. In some non-depicted examples, more than one induction coil extends through at least one air gap of air gaps904.

Turning now toFIG. 10, an illustration of a side view of an expansion joint of a contoured smart susceptor of a tooling die is depicted in accordance with an illustrative embodiment. In some illustrative examples, view1000is a side view of a portion of tooling die700ofFIGS. 7 and 8. View1000may be an alternative arrangement to view900ofFIG. 9.

Induction coils1001and conduits1002run through air gaps1004formed by adjacent dielectric laminates of plurality of dielectric laminates1006. As depicted, induction coils1001are positioned in every air gap of air gaps1004. As depicted, conduits1002are positioned in every air gap of air gaps1004. As depicted, induction coils1001and conduits1002run through the same air gaps of air gaps1004. For example, conduit1007and induction coil1008are present in air gap1010. As depicted, only a single induction coil of induction coils1001is positioned in a single air gap. For example, only induction coil1008is positioned within air gap1010.

Although view1000is described as a side view of tooling die700, a side view of tooling die700may have alternative non-depicted embodiments. For examples, tooling die700may have any desirable quantity of induction coils1001. In some non-depicted examples, induction coils1001and may run through additional air gaps of air gaps1004. In some non-depicted examples, more than one induction coil extends through at least one air gap of air gaps1004. In some non-depicted examples, the quantity of induction coils1001is different than the quantity of conduits1002. In some non-depicted examples, some of air gaps1004may not include a conduit of conduits1002. In some non-depicted examples, some of air gaps1004may not include an induction coil of induction coils1001.

The different components shown inFIGS. 2-10may be combined with components inFIG. 1, used with components inFIG. 1, or a combination of the two. Additionally, some of the components inFIGS. 2-10may be illustrative examples of how components shown in block form inFIG. 1can be implemented as physical structures.

Turning now toFIG. 11, an illustration of a flowchart of a method for processing a structure is depicted in accordance with an illustrative embodiment. Method1100may be implemented by tool106ofFIG. 1. Method1100may be implemented using tooling die200ofFIG. 2. Method1100may be performed in induction tool300ofFIGS. 3-6. Method1100may be performed using tooling die700ofFIGS. 7-10.

Method1100heats a structure in a tool (operation1102). Method1100quenches the structure in the tool such that a shape of the structure is maintained, in which quenching is performed by contacting the structure with a quenching medium (operation1104). Afterwards the method terminates.

In some illustrative examples, heating the structure comprises inductively heating smart susceptors of the tool in contact with the structure (operation1106). In some illustrative examples, the structure is a metallic structure, and wherein heating and quenching the structure in the tool comprises solution heat treating the metallic structure (operation1108).

In some illustrative examples, quenching the structure in the tool comprises flowing a quenching medium through apertures in smart susceptors of the tool (operation1110). The quenching medium takes any desirable form. In some illustrative examples, the quenching medium is water. In some illustrative examples, quenching the structure in the tool comprises quenching the structure while the structure is held in a fixed position (operation1114). In some illustrative examples, quenching the structure in the tool comprises flowing the quenching medium through apertures designed to maintain surface characteristics of the structure (operation1112).

In some illustrative examples, when the tool is an induction tool, method1100loads the structure into the induction tool (operation1116). In some illustrative examples, method1100moves at least one of a first tooling die of the induction or a second tooling die of the induction tool relative to each other to close the induction tool (operation1118).

Turning now toFIG. 12, an illustration of a flowchart of a method for processing a structure is depicted in accordance with an illustrative embodiment. Method1200may be implemented to form tool106ofFIG. 1. Method1200may be implemented to form tooling die200ofFIG. 2. Method1200may be performed to form induction tool300ofFIGS. 3-6. Method1200may be performed to form tooling die700ofFIGS. 7-10.

Method1200positions a plurality of dielectric laminates such that air gaps are defined between adjacent laminates (operation1202). Method1200connects a ceramic facing to at least some of the plurality of dielectric laminates (operation1204). Method1200disposes induction coils in some of the air gaps formed between adjacent dielectric laminates, wherein each induction coil of the induction coils extends through a single air gap (operation1206). Method1200places a contoured smart susceptor in contact with the ceramic facing to form a first tooling die, the contoured smart susceptor having a curve in a first cross-sectional direction (operation1208). Afterwards the method terminates.

In some illustrative examples, method1200loads a structure into an induction tool including the first tooling die (operation1210). In some illustrative examples, method1200heats the structure using the contoured smart susceptor and the induction coils (operation1212). In some illustrative examples, method1200quenches the structure in the induction tool such that a shape of the structure is maintained, wherein quenching the structure in the tool comprises flowing a quenching medium through apertures in smart susceptors of the tool (operation1214). In some illustrative examples, the structure is a component of an aircraft (operation1216).

In some illustrative examples, method1200forms apertures in the contoured smart susceptor, wherein the apertures are configured to allow a quenching medium to quench a surface of a structure in contact with the contoured smart susceptor (operation1218). In some illustrative examples, the apertures are designed to maintain surface characteristics of the structure (operation1220).

In some illustrative examples, method1200supports the contoured smart susceptor with a plurality of bridging strips, wherein the plurality of bridging strips each extend over multiple air gaps (operation1222). In some illustrative examples, method1200forms the induction coils such that each of the induction coils has a respective curve following the curve of the contoured smart susceptor in the first cross-sectional direction (operation1224).

In some illustrative examples, not all blocks of method1100or method1200are performed. For example, each of operations1106-1118inFIG. 11may be optional operations of method1100. As another example, each of operations1210-1224may be optional operations of method1200.

Illustrative embodiments of the present disclosure may be described in the context of aircraft manufacturing and service method1300as shown inFIG. 13and aircraft1400as shown inFIG. 14. Turning first toFIG. 13, an illustration of an aircraft manufacturing and service method is depicted in accordance with an illustrative embodiment. During preproduction, aircraft manufacturing and service method1300may include specification and design1302of aircraft1400inFIG. 14and material procurement1304.

During production, component and subassembly manufacturing1306and system integration1308of aircraft1400takes place. Thereafter, aircraft1400may go through certification and delivery1310in order to be placed in service1312. While in service1312by a customer, aircraft1400is scheduled for routine maintenance and service1314, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

With reference now toFIG. 14, an illustration of an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft1400is produced by aircraft manufacturing and service method1300inFIG. 13and may include airframe1402with a plurality of systems1404and interior1406. Examples of systems1404include one or more of propulsion system1408, electrical system1410, hydraulic system1412, and environmental system1414. Any number of other systems may be included. Although an aerospace example is shown, different illustrative embodiments may be applied to other industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method1300. One or more illustrative embodiments may be used during any of component and subassembly manufacturing1306, system integration1308, or maintenance and service1314ofFIG. 13. For example, induction tool108ofFIG. 1may be used to heat treat and quench a structure during component and subassembly manufacturing1306. As another example, induction tool108ofFIG. 1may be used to heat treat and quench replacement parts during maintenance and service1314ofFIG. 13.

Apparatuses and methods embodied herein may be employed in manufacturing at least one component of aircraft1400. For example, induction tool108ofFIG. 1may be used to manufacture a portion of at least one of airframe1402or interior1406. For example, structure100may be a portion of airframe1402or interior1406.

The illustrative examples enable an aluminum lip skin type structure to be solution treated and quenched with dimensional control of the part. The induction coils in the induction tool could run perpendicular to the lip bend to provide more even heating.

Quenching of the metallic structure is achieved through a quenching system which includes a quenching medium that quickly quenches the metallic part after heating. The illustrative examples use induction heat treatment with the laminated tooling where the metallic structure is held fixed in position while quenched.