US 12,409,618 B2
Method of forming composites by joule heating of enveloping metallic sheets
Kerrick Dando, Wichita, KS (US); Rahbar Nasserrafi, Wichita, KS (US); Mark Anthony Wadsworth, Wichita, KS (US); and Gerald Hicks, Wichita, KS (US)
Assigned to Spirit AeroSystems, Inc., Wichita, KS (US)
Filed by Spirit AeroSystems, Inc., Wichita, KS (US)
Filed on Mar. 8, 2023, as Appl. No. 18/119,205.
Prior Publication US 2024/0300195 A1, Sep. 12, 2024
Int. Cl. B29C 70/44 (2006.01); B29C 70/54 (2006.01)
CPC B29C 70/544 (2021.05) [B29C 70/44 (2013.01); B29C 70/545 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method of manufacturing a complex-shaped composite part, the method comprising:
applying a metallic sheath around at least two opposing surfaces of a workpiece, wherein the workpiece is a composite laminate;
applying an electric current through the metallic sheath to heat the workpiece;
shaping the workpiece in the metallic sheath into the complex-shaped composite part; and
cooling the complex-shaped composite part;
wherein shaping comprises at least partially drawing the metallic sheath through non-conductive rollers, biased against at least one side of the metallic sheath and located at opposing edge regions of the metallic sheath, toward a non-conductive tooling surface and then fully compressing the metallic sheath with the workpiece therein against the non-conductive tooling surface while electric current is applied through the workpiece.