Mr. Thomas F. Grapes Profile

Thomas F. Grapes

at Northrop Grumman Corp

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Proceedings Article | 12 December 2003 Paper

Diffusion-bonded beryllium aluminum optical structures

Thomas Grapes

Proceedings Volume 5179, (2003) https://doi.org/10.1117/12.508495

KEYWORDS: Diffusion, Aluminum, Beryllium, Solids, Metals, Optics manufacturing, Interfaces, Titanium, Manufacturing, Structural design

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Beryllium aluminum material can present significant advantages for optical support structures. A very likely advantage of beryllium aluminum compared to aluminum or titanium for such structures is its higher specific stiffness. However, beryllium aluminum material is significantly more expensive than most competing materials. The cost problem with beryllium aluminum is exacerbated if structural fabrication methods that result in near net shape parts are not used. Near net shape methods result in the least amount of material “thrown away” in the fabrication process. Casting is a primary example of near net shape manufacturing that is appropriate for certain optical support structures. Casting aluminum, and other materials as well, is common. Casting of beryllium aluminum is very difficult, however, and has not had significant success. Diffusion bonding -- a different approach for achieving near net shape beryllium aluminum optical support structures, was pursued and accomplished. Diffusion bonding is a term used to describe the joining of solid metal pieces under high temperature and pressure, but without melting. Three different optical support structures were designed and built of beryllium aluminum using diffusion bonding. Relatively small solid beryllium aluminum pieces were arranged together and then joined under hot isostatic pressure conditions. The resulting relatively large diffusion bonded part was then machined to achieve the final product. Significant cost savings as compared to machining the part from a solid block were realized. Difficulties achieving diffusion bonds in complex joints were experienced and addressed.

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