text:
|Publication number
|Publication type
|Application number
|Publication date
|Aug 11, 1998
|Filing date
|Jun 6, 1995
|Priority date
|Apr 5, 1991
|Fee status
|Also published as
|Publication number
|Marc R. Matsen, Douglas A. McCarville
|Original Assignee
|The Boeing Company
|Export Citation
|BiBTeX, EndNote, RefMan
|Patent Citations (166), Non-Patent Citations (11), Referenced by (28), Classifications (127), Legal Events (5)
|External Links: USPTO, USPTO Assignment, Espacenet
The present application is a continuation-in-part application based upon U.S. patent application Ser. No. 08/169,655, filed Dec. 16, 1993, now U.S. Pat. No. 5,530,227 (which was a continuation-in-part application of U.S. patent application Ser. No. 07/777,739, filed Oct. 15, 1991) now U.S. Pat. No. 5,410,132. The present application also is a continuation-in-part application based upon U.S. patent application 08/092,050, filed Jul. 15, 1993, now U.S. Pat. No. 5,410,133 and a divisional of U.S. patent application Ser. No. 07/681,004, filed Apr. 5, 1991, now U.S. Pat. No. 5,229,562. Finally, the present application is also a continuation-in-part application based upon U.S. patent application Ser. No. 08/151,433, filed Nov. 12, 1993 now U.S. Pat. No. 5,420,400. We incorporate these applications and patent by reference.
The present invention is a method for bonding metal or composite structures, including both thermosets and thermoplastics, using induction heating to heat the workpieces efficiently and rapidly and, thereby, to reduce the bonding operations time and cost.
Fiber-reinforced organic resin matrix composites have a high strength-to-weight ratio or high stiffness-to-weight ratio and desirable fatigue characteristics that make them increasingly popular as a replacement for metal in aerospace applications where weight, strength, or fatigue is critical. Composites today, however, are expensive. There is a need for improved manufacturing processes to reduce touch labor and the forming time.
Prepregs combine continuous, woven, or chopped fibers with an uncured matrix resin, and usually are fiber sheets with a thin film of the matrix. Sheets of prepreg generally are placed (laid-up) directly upon a tool or die having a forming surface contoured to the desired shape of the completed part or are laid-up in a flat sheet which is then draped and formed over the tool or die to the contour of the tool. Lay up can be by hand or with specialized tow or tape placement equipment. Then the resin in the prepreg lay up is consolidated (i.e., cured) in a vacuum bag process in an autoclave (i.e., a pressure oven) to complete the part.
The tools or dies for metal or composite processing typically are formed to close dimensional tolerances. They are massive, must be heated along with the workpiece, and must be cooled prior to removing the completed part. The delay caused to heat and to cool the mass of the tools adds substantially to the overall time necessary to fabricate each part. These delays are especially significant when the manufacturing run is low rate where the dies need to be changed after producing only a few parts of each kind.
In hot press forming, the prepreg is laid-up, bagged (if necessary), and placed between matched metal tools that include forming surfaces that define the internal, external, or both mold lines of the completed part. The tools and composite preform are placed within a press and then the tools, press, and preform are heated. By "preform" we mean the prepreg lay up.
The tooling in autoclave or hot press fabrication is a significant heat sink that consumes substantial energy. Furthermore, the tooling takes significant time to heat the composite material to its consolidation temperature and, after curing the composite, to cool to a temperature at which it is safe to remove the finished composite part.
As described in U.S. Pat. No. 4,657,717, a flat, composite prepreg panel was sandwiched between two metal sheets made from a superplastically formable alloy, and formed against a die having a surface precisely contoured to the final shape of the part.
Attempts have been made to reduce composite fabrication times by actively cooling the tools after forming the composite part. These attempts have shortened the time necessary to produce a composite part, but the time for and cost of heating and cooling remain significant contributors to overall fabrication costs. Designing and making tools with active cooling increases their cost.
Boeing described a process for organic matrix forming and consolidation using induction heating in U.S. patent application Ser. No. 08/169,655. There, prepregs were laid up in a flat sheet and were sandwiched between aluminum susceptor facesheets. To ensure an inert atmosphere around the composite during curing and to permit withdrawing volatiles and outgassing from around the composite during the consolidation, we welded the facesheets around their periphery. Such welding unduly impacts the preparation time and the cost for part fabrication. It also ruined the facesheets (i.e., prohibited their reuse). The present invention is a technique that readily and reliably seals the facesheets without the need for welding and permits reuse of the facesheets in certain circumstances. Our "bag-and-seal" technique applies to both resin composite and metal processing, especially in our induction heating workcell.
For purposes of this description, we use "consolidation" to mean pressure compacting and curing of an organic matrix resin through thermally activated chemical reactions to produce a stable composite. By "forming," we mean shaping the composite or metal and retort in its plastic state. "Forming" may entail superplastic forming, drawing, or some other shaping operation, as those skilled in the art will understand.
Airplanes are commonly made from metal or composite with prefabricated parts assembled and fastened or riveted together. The labor cost for fastening is a significant cost element and the fasteners add weight that limits overall performance and capability or adversely impacts operational costs. For military aircraft, weight translates to payload/range which is critical with modern technology with a small advantage can mean the difference between success and failure. For commercial aircraft, while weight does not translate to survivability, it is still a significant factor because the capital cost plus the operating cost are the key elements of the airlines expense. Technologies to reduce cost and weight, accordingly, are dear in the aircraft industry. The present invention is a bonding operation using Boeing's induction heating workcell which promises significant cost and weight savings for the manufacture of aerospace parts and assemblies.
While graphite or boron fibers can be heated directly by induction, most organic matrix composites require a susceptor in or adjacent to the composite material preform to achieve the necessary heating for consolidation or forming. A retort of sealed susceptor sheets is also desirable for metal workpieces to control the atmosphere around the workpiece and to achieve uniform heating. The susceptor is heated inductively and transfers its heat principally through conduction to the preform or workpiece that is sealed within the susceptor retort. While the metals in the workpiece may themselves be susceptible to induction heating, the metal workpiece needs to be shielded in an inert atmosphere during high temperature processing to avoid oxidation of the metal, so we usually enclose the workpiece (one or more metal sheets) in a metal retort when using our ceramic tooling induction heating press. Enclosed in the metal retort, the workpiece does not experience the oscillating magnetic field which instead is absorbed in the retort sheets. Heating is by conduction from the retort to the workpiece.
Induction focuses heating on the retort (and workpiece) and eliminates wasteful, inefficient heat sinks. Because the ceramic tools in our induction heating workcell do not heat to as high a temperature as the metal tooling of conventional, prior art presses, problems caused by different coefficients of thermal expansion between the tools and the workpiece are reduced. Furthermore, we are energy efficient because significantly higher percentages of our input energy goes to heating the workpiece than occurs with conventional presses. Our reduced thermal mass and ability to focus the heating energy permits us to change the operating temperature rapidly which improves the products we produce. Finally, our shop environment is not heated as significantly from the radiation of the large thermal mass of a conventional press.
In induction heating for consolidating and/or forming organic matrix composite materials, we place a thermoplastic organic matrix composite preform of PEEK or ULTEM, for example, adjacent a metal susceptor. These thermoplastics have a low concentration of volatile solvents and are easy to use. The susceptor facesheets of the retort are inductively heated to heat the preform. We apply consolidation and forming pressure to consolidate and, if applicable, to form the preform at its curing temperature. Generally, we enclose the preform between two susceptor sheets that are sealed to form a pressure zone. We call this assembly a "retort." We evacuate the pressure zone in the retort in a manner analogous to conventional vacuum bag processes for resin consolidation, or, for resins with low volatiles resins, like ULTEM, we can pressurize this zone to enhance consolidation. The retort is placed in an induction heating press on the forming surfaces of dies having the desired shape of the molded composite part. After the retort (and preform) are inductively heated to the desired elevated temperature, we apply differential pressure (while maintaining the vacuum in the pressure zone around the preform) across the retort which functions as a diaphragm in the press to form the preform against the die into the desired shape of the completed composite panel.
The retort often includes three susceptor sheets sealed around their periphery to define two pressure zones. The first pressure zone surrounds the composite panel/preform or metal workpiece and is evacuated and maintained under vacuum. The second pressure zone is pressurized (i.e., flooded with gas) at the appropriate to help form the composite panel or workpiece. The shared wall of the three layer sandwich that defines the two pressure zones acts as a diaphragm in this situation.
In preparing the retort, as described in U.S. patent application Ser. No. 08/341,779, we often use temporary seals to hold the sheets until the sheets are clamped into the press, and we prefer a "C" spring clamp. The clamp sandwiches the outer susceptor sheets of the retort and provides a compressive force to hold the retort together temporarily, pressing the sheets against an "O" ring gasket. Such a gasket seats between susceptor sheets in a machined or formed groove or crimp around the periphery of adjacent susceptors. For processing below about 600� F. (315� C.), the gasket is generally silicone rubber. Between about 600� F. (315� C.) and 1300� F. (705� C.), the gasket is copper; above about 1300� F. (705� C.), the gasket is stainless steel. The gasket and susceptor sheets abut and form a gas seal via the compressive force of the die set. The "C" clamp permits handling of the retort in and out of the die set. The "C" clamp also provides a current path from the top sheet to the bottom sheet (when the gasket is rubber or stainless steel). The "C" clamp can be omitted when we use a copper gasket, but handling the susceptor sheets is more difficult. The "C" clamp jumper is only required for electrical continuity when the gasket is not an electrical conductor and, then, only on the edges of the retort transverse to the induction coils since the coils induce eddy currents in the susceptor that flow parallel to the coils. We can perform a wide range of manufacturing operations in our induction heating press. These operations have optimum operating temperatures ranging from about 350� F. (175� C.) to about 1950� F. (1068� C.). For each operation, we usually need to hold the temperature relatively constant for several minutes to several hours while we complete the operations. While we can achieve temperature control by controlling the input power fed to the induction coil, we have discovered a better and simpler way that capitalizes on the Curie temperature. By judicious selection of the metal or alloy in the retort's susceptor facesheets, we can avoid excessive heating irrespective of the input power. With improved control and improved temperature uniformity in the workpiece, we produce better products.
As described to some degree in U.S. Pat. 4,622,445 and U.S. Pat. No. 5,410,132, we discovered an improvement for an SPF process coupling the use of ceramic dies with inductive heating. With our inductively heated SPF press or workcell, we can heat preferentially the sheet metal workpiece with induction heating without heating the platens or dies significantly and can use the ceramic dies as an insulator to hold the induced heat in the part. We can stop the heating at any time and can cool the part relatively quickly even before removing it from the die. We do not waste the energy otherwise required to heat the large thermal mass of the platens and dies. We do not force the press operators to work around the hot dies and platens. With our inductive heating workcell, we also save time and energy when changing dies to set up to manufacture different parts because the dies and platen are significantly cooler than those in a conventional SPF press. We shorten the operation to change dies by several hours. Therefore, the induction heating process is an agile work tool for rapid prototyping or low rate production with improved efficiency and versatility.
U.S. Pat. Nos. 3,920,175 and 3,927,817 describe typical combined cycles for SPF forming and diffusion bonding. Diffusion bonding is a notoriously difficult and temperamental process that has forced many SPF fabricators away from multisheet manufacturing or to "clean room" production facilities and other processing tricks to eliminate the possibility of oxidation in the bond. Oxides foul the integrity of the bond. In addition, diffusion bonds are plagued with microvoids which are difficult to detect nondestructively, but, if present, significantly diminish the structural performance of the joint. Diffusion bonding also is a time consuming process. The part typically must be held at elevated temperature and elevated pressure (about 400 psi) for several hours. For example, in U.S. Pat. No. 3,920,175, the diffusion bonding operation takes five hours at 1650� F. (900�C.), making the forming/bonding operation six hours. In U.S. Pat. No. 3,927,817, diffusion bonding occurs prior to forming, still requires four to five hours, and forces a six hour bonding/forming cycle at 1650� F. (900� C.) for the entire period. Typically a hot press diffusion bonding process for common titanium alloys used in aerospace applications will require over eight hours at 2500 psi and 800� C. (1472� F.), about six hours at 400 psi and 900� C. (1650� F.), or about two hours at 250-300 psi and 950� C. (17420� F.). Producing this heat and pressure for this length of time is expensive.
The present invention is a timesaving process that promises higher quality parts at lower production costs with significant energy savings in shorter production times. The troubles of diffusion bonding are eliminated by replacing diffusion bonding with brazing so that a much more efficient manufacturing cycle is possible. Manufacturers have greater assurance in the integrity of the brazed bond. To achieve a satisfactory brazed bond quickly and reliably, we focus the heating on the part we are forming using an induction heater. We hold the part within insulating ceramic dies that are transparent to the time-varying magnetic field that our induction heater produces. We significantly reduce cycle time in manufacturing modern aerospace parts.
Our workcell can function with both metals and composites and has considerable versatility and agility with respect to the manufacturing operations performed and the operating temperature.
In a method of the present invention for bonding organic matrix composite materials, prefabricated resin composite parts (thermosets or thermoplastics) are assembled to define a bondline (for thermosets) or weld line (for thermoplastics). Along the bondline/weld line, we place an adhesive or a thermoplastic which we melt in the bonding operation to join the prefabricated composite parts together. We place this assembly of the prefabricated composite parts and adhesive/weldment within a metal susceptor retort that we seal in accordance with our earlier inventions. We might also use some or all uncured or partially cured parts. When we intend to heat the adhesive/weldment until it melts in the bonding regions and do not want to melt the prefabricated composite parts in regions remote from the bondline/weldline, we place susceptor shims on the assembly to relieve the composite parts from (i. e., lift off the surface of) the metal susceptor sheets in regions other than the bonding/weld line. We load the retort in the induction heating workcell, energize the coil to heat the susceptor, and, in turn the adhesive/weldment while pressing the assembly (at least in the regions of the bondline) to form the bond upon cooling, and de-energize the coil to cool the retort with whatever cooling profile we prefer.
Because of our capability with induction heating to rapidly heat and cool, we significantly reduce the processing time over conventional autoclave bonding operations in fabricating thermoset honeycomb panels. While we can heat to 375� F. (190� C.) in about 15 min. with our workcell, an autoclave takes about 180 min.; twelve times as long. Therefore, we can shorten the bonding cycle time from as much as 300 min to about 90 min, a reduction of 70%. Time translates directly into cost. For thermoplastic bonding, the cycle time reduction is from about 240 min to 30 min (an 87% reduction).
The retort may include three susceptor sheets sealed around their periphery to define two pressure zones. The first pressure zone surrounds the composite panel/preform or metal workpiece and is evacuated and maintained under vacuum. The second pressure zone is pressurized (i.e., flooded with gas) to help form the composite panel or workpiece. The shared wall of the three layer sandwich acts as a diaphragm in this situation.
For metal bonding, the assembly is similar. Between the prefabricated metal parts, however, we use a braze alloy or an organic matrix resin adhesive. We heat the susceptor much hotter than with resin composite parts, if we are brazing, and usually apply a higher pressure, but we focus heating along the bondline with the appropriate placement of the shims. The shims conduct heat rapidly from the susceptor to the part in the location(s) of the bondline while the relief that the shims provide in other locations forces convection and radiation to be the primary heat transfer mechanism to such regions by using shims, we obtain higher pressure at the bondline than at locations remote from the shims without changing the die contour or configuration.
We can also glue metal parts together with a hot melt resin adhesive. In this case, we either heat the part directly with induction or we use a susceptor to heat the confined part or we use a bondline susceptor that is responsive to induction heating. We apply the adhesive to prepared surfaces and press the parts together with the dies or with diaphragm pressure from pressure zones in the encasing retort. We can bond virtually any metals this way rapidly using our relatively inexpensive, flexible (multifunctional) tooling.
FIG. 1 is a perspective view of our induction heating workcell.
FIG. 2 is a schematic cross-sectional view of the apparatus of FIG. 1.
FIG. 3 is a schematic sectional view of our induction heating workcell showing a typical detail of the edge sealing for our susceptor retort.
FIG. 4 is another schematic sectional view, similar to FIG. 3, showing a copper gasket which allows us to eliminate the "C" clamp used in FIG. 3.
FIG. 5 is another schematic sectional view showing bonding of a beaded panel using our induction heating workcell.
FIG. 6 is another schematic sectional view showing bonding of a honeycomb panel to thermoset skins using our induction heating workcell.
FIG. 7 is yet another schematic sectional view showing adhesive bonding of an airfoil, such as two machined halves of an aluminum missile wing.
1. The Induction Heating Process
In FIG. 1, an induction heating workcell 10 includes tools or dies 20 and 22 mounted within an upper 24 and a lower 26 strongback. The strongbacks are each threaded onto four threaded column supports or jackscrews 28 or they float free on the columns and are fixed with nuts. We can turn the jackscrews to move one strongback relative to the other. The strongbacks 24 and 26 provide a rigid, flat backing surface for the upper and lower dies 20 and 22 to prevent the dies from bending and cracking during manufacturing operations. Preferably, the strongbacks hold the dies to a surface tolerance of �0.003 inches per square foot of the forming surface. Such tolerances are desirable to achieve proper part tolerances. The strongbacks may be steel, aluminum, or any other material capable of handling the loads present during forming or consolidation, but we prefer materials that are non-magnetic to avoid any distortion to the magnetic field that our induction coils produce. In some circumstances, the dies may be strong enough themselves that strongbacks are unnecessary. The strongbacks transfer pressure input through the columns evenly to the dies.
The dies 20 and 22 are usually ceramic and are reinforced with a plurality of fiberglass rods 32 that are held with bolts 74 and that extend both longitudinally and transversely in a grid through each die. Each die usually is framed with phenolic reinforcement 72 as well to maintain a compressive load on the die. Each die may be attached to its strongback by any suitable fastening device such as bolting or clamping. In the preferred embodiment, both dies are mounted on support plates 76 which are held in place on the respective strongbacks through the use of clamping bars 77. The clamping bars 77 extend around the periphery of the support plates 76 and are bolted to the respective strongbacks through the use of fasteners (not shown).
The dies should not be susceptible to inductive heating so that heating is localized in the retort. We prefer a ceramic that has a low coefficient of thermal expansion, good thermal shock resistance, and relatively high compression strength, such as a castable fused silica ceramic.
We embed portions of an induction coil 35 in the dies. In the illustrated embodiment, we use four separate induction segments, but the number can vary. Each segment is formed from a straight tubing section 36 that extends along the length of each die and a flexible coil connector 38 that joins the straight tubing sections 36 in the upper die 20 to the corresponding straight tubing section in the lower die 22. Connectors 40 located at the ends of the induction coil 35 connect the induction coil 35 to an external power source or coil driver 50 and to a coolant source.
Cavities 42 and 44 in the respective dies can hold tool inserts 46 and 48. The upper tool insert 46 in some applications has a contoured forming surface 58 that has a shape corresponding to the desired shape of the outer mold line surface of the completed composite. The lower tool insert usually determines the inner mold line. The tool inserts also should not be susceptible to inductive heating, preferably being formed of a castable ceramic. In some cases, both the dies and the tool inserts can be made from a matrix resin rather than from a as forming or consolidating certain organic matrix composites. We prefer cast ceramic tooling which provides the greatest flexibility and versatility for the induction heating workcell. The forming surfaces can be an integral part of the dies.
Each die surrounds and supports the respective tool insert and holds the straight sections 36 of the induction coil in proper position in relationship to the tool insert 46 or 48. In the preferred embodiment, the interior 70 of the dies is formed of a castable phenolic or ceramic and the exterior sides from precast composite phenolic resin blocks 72. In some applications, we prefer to reinforce the phenolic or ceramic with chopped fibers or non-woven or woven reinforcing mats.
FIG. 2 shows a retort 60 between the tool inserts 46 and 48. The retort 60 includes an organic matrix composite panel or metal workpiece sandwiched with susceptor facesheets. The retort is heated to the operating temperature by energizing the coil 35. In the case of a composite panel, when the panel reaches the bonding temperature where the adhesive melts or the theromplastic resin flows, we can apply gas pressure to the outer surfaces of the retort by pressure sources 52 and 54 to focus the workpiece in regions remote from the bondline. Pressure source 52 applies pressure to the upper surface of the retort 60 through a conduit 62 that passes through the upper die 20 and upper tool insert 46, while pressure source 54 applies a pressure to the lower surface of the retort 60 through a conduit 64 that passes through the lower die 22 and lower tool insert 48. The pressure applied to the retort 60 is maintained until the retort has formed to the contour of the forming surface 58 and the matrix resin has consolidated. The pressure sources 52 and 54 generally apply a differential pressure to the retort 60.
Pin holes (not shown) in the tool inserts vent gas trapped between the retort 60 and the forming surface 58 as the retort deforms. Such pin holes can be coupled to a flow meter to monitor the progress of the deformation.
When the bonding is complete, the induction coil 35 is de-energized and the pressure relieved. The tool inserts and dies are separated. We remove the formed retort 60 from the press and recover the composite part from between the susceptor facesheets.
An alternating oscillating electrical current in the induction coil 35 produces a time varying magnetic field that heats the susceptor sheets of the retort via eddy current heating. The frequency at which the coil driver 50 drives the coils 35 depends upon the nature of the retort 60. We power the coil with up to about 400 kW at frequencies of between about 3-10 kHz. Current penetration of copper at 3 kHz is approximately 0.06 inches (1.5 mm), while penetration at 10 kHz is approximately 0.03 inches (0.75 mm).
The shape of the coil has a significant effect upon the magnetic field uniformity. Field uniformity usually is important because temperature uniformity induced in the retort is directly related to the uniformity of the magnetic field. Uniform heating insures that different portions of the workpiece will reach the operating temperature at approximately the same time. Solenoid type induction coils like those we illustrate provide a uniform magnetic field, and are preferred. Greater field uniformity is produced in a retort that is located symmetrically along the centerline of the surrounding coil. Those of ordinary skill can establish series/parallel induction coil combinations, variable turn spacing, and distances between the part and the induction coil by standard electrical calculations to achieve the desired heating from whatever coil configuration is used.
The tool inserts and dies are usually substantially thermally insulating and trap and contain heat within the retort. Since the dies and tool inserts are not inductively heated and act as insulators to maintain heat within the retort, the present invention requires far less energy to achieve the desired operating temperature than conventional autoclave or resistive hot press methods where the metal tooling is a massive heat sink.
Bonding operations using our workcell are faster than prior art operations because we do not heat the large thermal mass of either the dies or tool inserts. The retort is heated, the tool is not. Thus, the necessary processing temperature is achieved more rapidly. In addition, the highly conductive materials in the retort provide rapid heat transfer to the workpiece. When the driver 50 is de-energized, the dies and the retort cool rapidly to a temperature at which we can remove the retort from the workcell, saving time and energy over conventional systems. Coolant flowing through the coil tubes functions as an active heat exchanger to transfer heat out of the workpiece, retort, and dies. In addition, the thermal cycle is not as limited by the heating and cooling cycle of the equipment and tools so we can tailor the thermal cycle better to the process for which we are using the induction heating workcell.
2. Bonding Thermoplastic Resin Composites
In a bonding or bonding-and-forming process for organic (resin) matrix composites, a composite panel assembly is laid-up from individual prefabricated composite sheets. The composite panel assembly includes a thermoplastic sheet that functions as a bonding agent between the prefabricated parts. The assembly is placed between a first sheet 100 and second sheet 102 of a susceptor (usually aluminum, an aluminum alloy, or a "smart" susceptor) to form a retort. As shown in FIG. 4 & 5, the susceptor sheets are sealed around their periphery with a crimp and seal ring 110 formed into the susceptor sheets. A first pressure zone 117 between the susceptors 100 and 102 surrounds the composite panel.
In FIG. 4, the susceptor sheets 100 and 102 contact the dies, without leaving additional pressure zones between the outer susceptors and the dies, as we described with reference to FIG. 2. When additional pressure zones are used, these zones receive pressurized forming gas through a system of conduits fabricated in the dies as described in U.S. Pat. Nos. 4,708,008; 5,129,249; or 5,309,747 or 5,419,170, which we incorporate by reference. If the retort incorporates the necessary pressure zones to allow forming, the dies can be porous. Such dies do not need to carry or contain high pressure gases. They are lighter, are easier to make, and are less expensive.
Forming gas is introduced to pressure zone 118 between the two prefabricated composite panels 200, such as carbon-fiber reinforced PEEK thermoplastic sheets, through suitable pressure lines to deliver pressurized inert gas which forms the panel in its "bead" region simultaneously with bonding in the regions to the immediate left and right of pressure zone 118 and the "bead" region, as shown in FIG. 5.
Where we intend to form bonds between the panels 200 and 202, we sandwich a thermoplastic film 204 (generally ULTEM). Such a film should melt at a lower temperature than the thermoplastic in the panels 200 and 202 so that bonding can occur without delaminating the panels.
FIG. 5 shows an optional silicone rubber pressure pads 206 between the lower die and the lower susceptor sheet 102. We use these pads 206 to provide an even pressure across the entire bondline to correct for imperfections in the retort or dies that world otherwise leave isolated high spots. FIG. 5 also shows shim plates 208 between the lower susceptor sheet 102 and the panel 202 in the bondline region to provide relief in gap 10 between the lower panel 202 and the lower susceptor sheet in the "bead" zone remote from the bondlines.
While we have described that the part can be formed and bonded simultaneously, the operations can be done sequentially with forming preceding bonding. Sequential processing is simpler but slower.
We energize the coils with a time varying electrical field to produce a time varying magnetic field to heat the susceptors inductively to the bonding temperature of the composite panel. Heat is transferred by conduction and/or radiation from the susceptors into the composite panel, so it, too, reaches bonding temperature. The shims transfer heat faster to the bondline so the ULTEM film bonding agent melts before the remote "bead" regions heat to their delaminating temperature.
After completing bonding, we de-energize the induction coils and cool the retort and tool inserts to freeze the bonding agent (e.g., the adhesive, thermoplastic, or braze alloy) in the joint. Then we remove the retort from the tool inserts. Although there is some heat transfer between the retort and the tool inserts, it is insufficient to heat the tool inserts or dies significantly because the dies are such good thermal insulators. Therefore, the retort can quickly be pulled from the press. When the retort cools sufficiently, we remove the edge strips and recover the completed part. Often the edge strips and the susceptor sheets are reusable.
In one example of composite bonding in accordance with the present invention, we bonded two composite panels each comprising 48 layers of thermoplastic PEEK.IM6 prepreg 3/8 inch thick. Two aluminum sheets having a thickness of 1/16 inch were placed around the composite panel and aluminum shims were positioned in the bondline region between the lower susceptor and lower PEEK panel as shown in FIG. 5. We used a pressure pad as previously described and placed the retort in the tool inserts and inductively heated the assembly to a temperature of 550� F. in 15 minutes We maintained the retort at 550� F. for two minutes and then cooled it for 15 minutes. When we reached the bonding temperature of 550� F., we applied a constant pressure of about 100 psi within pressure zone 117 until the part was cool. These times and pressures are representative only and would differ depending upon the composite material used and the thickness and complexity of the bonded part.
The present invention is applicable to all types of organic matrix composites including both thermosetting and the thermoplastic composites such as epoxies, bismaleimides, polyimides, PEEK, PEK, PEKK, PES, or the like. If the materials have high solvent concentrations or the resins emit volatiles when they cure, we need to "bag" the workpiece to permit egress of these volatiles. Therefore, we prefer using resins with low volatiles that are true thermoplastics, like PEEK.
We can bond metals in a comparable process that we will describe in greater detail in section 4.
3. Bonding (i.e., curing) Thermosetting Resin Composite Honeycomb Panels
FIG. 6 illustrates the bonding of thermoset facesheets 300 and 302 to a honeycomb core 304 using an adhesive film 306 in a cobond operation. The thermoset sheets and core are contained within two "6061" aluminum alloy susceptor sheets with silicone or Shinitzu rubber overlay 308 configured to provide a lay-up of substantially constant thickness despite changes in the part configuration. FIG. 6 shows a three susceptor sheet retort with two sheets 310 and 312 defining a pressure zone in which we can inject argon gas 314 to increase the bonding pressure. Bonding pressure is transferred through the susceptor 310 to the rubber overlay 308 and into the upper thermoset sheet 300 when the temperature activates adhesive, typically around 375� F. for adhesives used with epoxy thermosets. The third susceptor sheet 316 underlies the facesheet 302. The bonding time is about 1 hour with heatup and cool-down taking about 15 min. each for a total cycle time of 90 mins.
The surface of an aircraft wing skin must be maintained to a close tolerance to achieve an efficient aerodynamic surface. The tolerances of the inner mold line surface of the wing skin must also be maintained at a close tolerance at least in a buildup area where the wing skin will be joined to a spar to ensure that the wing skin and spar can be precisely joined. It is not critical, however, to control the inner mold line surface in areas where the wing skin is not attached to other structures. The composite panel has additional plies to define the buildup areas. The additional reinforce the composite panel in these areas which is necessary where a spar will be attached, and provide a convenient way to match the skin and spar to produce the desired outer wing configuration even if the spars are imprecise in their dimensions. We can fabricate built up areas at the faying surfaces to provide the precision fit, in which case we can eliminate shims.
4. Bonding Metals
a. Brazing
For brazing metal we prefer to use copper susceptor sheets about 0.032-0.062 inches thick, stainless steel, or a cobalt alloy "smart" susceptors as described in our pending U.S. patent application Ser. No. 08/469,604 entitled: "Method for Achieving Thermal Uniformity in Induction Processing of Organic Matrix Composites or Metals," Sometimes, the part itself can be the susceptor. Copper is a good susceptor and allows higher processing temperatures than aluminum or aluminum alloys. Copper also is an excellent susceptor material because it provides excellent heat transfer. Copper's excellent heat transfer properties help to ensure improved thermal uniformity. When processing metals, especially when using a copper retort at high temperatures, we typically use an inert atmosphere within the interior pressure zones to protect the copper and the parts being produced (i.e. the workpiece) against oxidation. That is, the inert gas purge protects the workpiece (and the copper retort materials) from oxygen damage. The susceptor can be a laminate of aluminum and copper. Aluminum outer sheets efficiently convert the magnetic energy to heat. The underlying copper sheets transfer the heat well from the aluminum skin to the metal or resin workpiece.
Brazing of metals is essentially the same process as that described for the bonding of organic matrix composites, so we will not repeat it here. We substitute a braze alloy for the thermoplastic film or thermoset adhesive, and form braze joints between the metal sheets at selected locations. We can combine brazing with forming or with other operations.
b. Adhesive bonding
As shown in FIG. 7, the present invention also contemplates adhering two metal parts together using a hot melt, organic matrix resin thermoplastic or thermoset adhesive. In FIG. 7, complementary machined aluminum missile fin halves 400 and 402 are bonded together with a thermoset adhesive 404 in the induction heating workcell. The adhesive is applied to the prepared surfaces that abut. In the process illustrated, we heat the parts directly with the induction coil 36 that surrounds the parts. This adhesive bonding process uses less expensive tooling than alternative processes, accomplishes the bonding in short thermal cycles, and is faster and cheaper than batch mode autoclave bonding operations. The process is just one more operation that one workcell can accomplish, thereby showing the versatility and agility of this flexible manufacturing workcell.
While we have described preferred embodiments, those skilled in the art will readily recognize alterations, variations, and modifications which might be made without departing from the inventive concept. Therefore, interpret the claims liberally with the support of the full range of equivalents known to those of ordinary skill based upon this description. The examples are given to illustrate the invention and not intended to limit it. Accordingly, limit the claims only as necessary in view of the pertinent prior art.
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|U.S. Classification
|219/633, 219/645, 219/672, 219/634
|International Classification
|Cooperative Classification
|European Classification
|Jun 6, 1995
Owner name: BOEING COMPANY, THE, WASHINGTON
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:MATSEN, MARC R.;MCCARVILLE, DOUGLAS A.;REEL/FRAME:007586/0309
Effective date: 19950606
|Feb 8, 2002
|Fee payment
Year of fee payment: 4
|Mar 5, 2002
|Maintenance fee reminder mailed
|Feb 13, 2006
|Fee payment
Year of fee payment: 8
|Jan 14, 2010
|Fee payment
Year of fee payment: 12


text:
Friend Tells offensive line to improve each day
Sept. 28, 2012
By Loran Smith
Georgia's offensive line, while playing well, faces a challenge which is likened to a hunter who does well when the target birds have been raised in a pen. He then is invited to hunt where the birds are wild and suddenly sees his marksmanship decline.
Thus far, the competition has not been what the Bulldogs will face in the coming weeks, starting Saturday against Tennessee. "Best team by far we have played," is the way Coach Will Friend sizes up the Volunteers. Like wild quail who fly higher and faster, Tennessee will bring a much better defense to Athens that what the Bulldogs have seen in its first four outings.
Interestingly, this week, more than a few critics are suggesting that the 4-0 Dawgs haven't really beaten anybody. While that may have some validity, the bigger question is, "Who is really good right now?" Nobody knows. Georgia is certainly a developing team which means that looking ahead could be like drinking hemlock. Many fans already have begun sipping heady wine. That is not a problem, unless the players begin to sup from the same cup.
Taking a positive stance, leads one to conclude that there is good news with the offensive line. Friend likes, first and foremost, the fact that his linemen "are playing hard." They are, he says, giving heart-warming effort. They care about each other, a term which has the greatest of value although the skeptics often scoff at such notion. When lineman care, they work together with more efficiency, and they are prone to do the little things which made a difference. Consider this caring thing trite if you like, but what chef could make a mouth watering pound cake without flour and sugar?
The Bulldog linemen are blessed with good karma, camaraderie and intelligence, all of which means they could become "real good." They themselves are trying to sustain their unwritten motto which Friend reminds them every day--"improve with each practice."
Summer camp began with inexperience hovering about. Only Kenarious Gates, Dallas Lee and Chris Burnett had any game action to speak off. Friend has tried to give the backup players, including Mark Beard, Watts Dantzler and Austin Long as many snaps as possible, especially when fourth quarter leads have enhanced opportunity. With center David Andrews, a pleasant surprise, and right tackle John Theus it has been on-the-job training, but now the real work begins.
With talent, competition and depth at running back, the line has confidence that if it gives Todd Gurley, Keith Marshall and Ken Malcome even a minimum of space, these gifted backs can move the chains. In the first four outings, downfield blocking by the receivers has been a notable plus which means the "team effort" appraisal has repeated itself all fall, no insignificant influence when it comes to points and yardage production.
The rapport of the linemen is bringing dividends to the offense and so is the rapport of Friend with offensive coordinator Mike Bobo. Their mutual admiration society counts, too. They have to manage the game plan every week, mindful of the fact that the pro style offense has come to the campus, but restricted to a total of 20 hours to get the job done and that includes football chores like meeting time and weight lifting.
Bobo, an affable man with a sterling reputation in the coaching profession, is quick to give friend a thumbs-up for the job Friend does. "Will," Bobo says, "is very demanding which you must be if you are going to succeed in this business. He expects a lot from his players, but he is fair and they appreciate that. He can relate to them, and, as a result, they play for him."
Bobo's parting compliment was that the Bulldog's O-Line coach has not had too many negative grades this season when it comes to missed assignments. This means fewer penalties, fewer sacks and more production. However, all of the aforementioned is aware that the forthcoming competition is like a wild quail--tougher to bring down.
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text:
Loners (comics)
|Publication information
|Marvel Comics
|First appearance
|Runaways (vol. 2) #1
|Created by
|Brian K. Vaughan
Adrian Alphona
|In-story information
|Current Members:
Rick Jones (sponsor)
Former Members:
Phil Urich
Geoffrey Wilder (magically posing as Chamber)
Loners (originally named Excelsior)[1] is a spin-off mini-series of comic books from Marvel Comics, first appearing in the pages of Runaways.[2] It consists of a Los Angeles-based support group for former teenage superheroes from New York, founded by Turbo of the New Warriors, and Phil Urich, the heroic former Green Goblin.[1] Their goals are initially stated to be to help fellow teenage superheroes to adjust to normal lives while coping with their powers, and to dissuade other superpowered teenagers from becoming heroes,[1] but these goals are discarded in their own miniseries in favor of the group apparently wanting to avoid using their powers for any reason,[3] even if that means abandoning helpless victims of crime to their fate.[4] Although all the characters were created by different authors and artists, the team itself was created by Brian K. Vaughan and Adrian Alphona, with other characters (Spider-Woman, Hollow, and Red Ronin) added to the cast during the events of the 2007 miniseries.
The group had originally appeared in the Runaways story arc "True Believers". At the end of the story arc, it was revealed that the group had secretly been sponsored by Rick Jones, on behalf of Captain America, who hoped to ensure the Runaways do not get into trouble.[5] Following their battle with Ultron, Rick Jones offered to sponsor the team full-time.[5] Its creative team is C. B. Cebulski (writer) and Karl Moline (artist).[6]
Originally debuting in the book Runaways under the name "Excelsior", the team later received their own limited series with an option to continue as an ongoing should sales be high enough, though this was not the case. The title of the series and the team was changed from Excelsior to Loners, due to trademark issues as Stan Lee holds a trademark on the term "Excelsior!",[7][8] though the team did appear in an issue of the third volume of Marvel Team-Up under the name Excelsior[9] before Loners was published. The title premiered on April 11, 2007 and ran for 6 issues. In a stylistic departure from their debut appearance in Runaways as comic relief, Loners is not a comedy, though the covers of the individual issues still suggest a light-hearted tone by being direct homages to the iconic imagery of the teen comedy feature films of John Hughes, and the exaggerated personalities from their Runaways debut are also retained entirely for the cast, though this does create some continuity discrepancies, particularly Darkhawk's infrequent lapses into potentially murderous violence[10] and sudden reversion to switching bodies in a manner that ignores later events from the Darkhawk series (this continuity gaffe even being referenced in Marvel Team-Up Vol.3 #15), and Julie Power no longer having the ability to teleport, her powers now including the ability to hover in the air without being in motion, and her character purporting to be from New York instead of the family home of Bainbridge Island, Washington.[11] In a further departure from both their debut appearance and their appearances elsewhere in Marvel titles as a fully functioning superhero group who gather in costume,[12] the group itself now has a completely different and unprecedented function, changing from a peer support/counseling group of active superheroes to an addiction/recovery group. It can be observed that the methods utilised by the group in many instances contradict common practices of individual empowerment found in addiction/recovery groups in favor of (ironically) codependency upon the group and its rituals. In the series, the "addiction" specified is addictive behavior: using superpowers, fighting crime, and helping those in need. The addictions are not to narcotic substance at any time during the series, although Mattie Franklin is seen getting drunk in a bar during the closing montage of issue 3 despite still being in high school, suggesting the possibility of alcohol dependence.
Julie Power and Johnny Gallo are also the subject of character retcons during the course of the series: whereas in his Runaways appearance Johnny's reasons for joining the group were given as being so he could be around other ex-teen heroes who had experienced early fame as a superhero and later couldn't cope without it,[13] this was revised in Loners to being that he used superheroics for thrill seeking and to meet women,[14] then revised a third time to being a response to his friend being killed during a superhero battle[14] (though this battle - occurring during the events of the 'Wolverine: Enemy of the State' story arc[15] - did not actually occur until after Johnny first appeared as a member of the Los Angeles-based Excelsior group, though he is portrayed during Loners in flashbacks as still living in New York at the time, working as a superhero alongside the friend in question: Eddie McDonough, who is also portrayed as being back in the Hornet armor he lost, somehow cured of the cerebral palsy which afflicted him). Julie's low intelligence displayed in the Runaways 'True Believers' story arc and the first three issues of Loners is also revealed as an affectation she adopts to fit in with the natives of Los Angeles and her fellow team-mates,[16] though she retains this personality for the rest of the series regardless of her revelation. Julie's age is also revised by several years, from the indeterminate "ex-teenage" of Runaways[13] to the specific age of 17,[16] and she no longer displays her teleportation powers,[17] or the ability to create shields.[18]
Three new team members were also introduced in the series: Penance (known as Hollow), Spider-Woman and Namie, the second version of the Red Ronin.[19] After the miniseries, The Loners appear in a special ten page Christmas story within the 2007 Marvel Holiday Special.[20]
After Mattie was killed and Darkhawk was severely injured (in "Grim Hunt" and The Thanos Imperative respectively), the remaining members of the team were inducted into the Avengers Academy by Hawkeye.[21]
- Rick Jones, on behalf of Captain America.
Original members[edit]
- Darkhawk (Chris Powell). He decided to give up his powers after his nightmares became too intense for him to handle. Chris is short-tempered and prone to violence, especially in his Darkhawk form, attacking not only his targets, but his own teammates. He later joins the New Avengers.
- Green Goblin (Phil Urich), the fourth, heroic, incarnation of the Green Goblin. After losing his costume and equipment during a battle, he finished college, earned a degree in journalism, and helped start Excelsior.[1] Was recently seen back in New York working for the Daily Bugle (formerly Front Line) and is the new Hobgoblin, who is working for Kingpin.[22]
- Lightspeed (Julie Power), formerly of Power Pack. Convinced that the superhero lifestyle robbed her of her childhood innocence, she left her family at 15 years old and moved to California, hoping to become an actress. Currently attending the Avengers Academy as a teacher's assistant.[21]
- Ricochet (Johnny Gallo), formerly of the Slingers. He is a mutant who has an early warning sense much like Spider-Man's, as well as acrobatic agility, dexterity with thrown objects, reflexes, and coordination.[1]
- Turbo (Michiko "Mickey" Musashi), formerly of the New Warriors. Deciding she would do more good with her education than she would through adventure, she retired the Torpedo armor and returned to investigative journalism.[23]
- Geoffrey Wilder, a time-displaced member of Runaways enemy The Pride, disguised as Jonothan "Jono" Starsmore, better known as Chamber, a former member of Generation X and the X-Men. Geoffrey only used the group as an opportunity to gain intelligence on the Runaways and never returned to them after the end of the "True Believers" arc. His false identity was hinted at by Molly Hayes when she asked who he thought he was fooling with his "fakey accent".
Later members[edit]
- Hollow, formerly known as Penance of Generation X. It is unknown who is now residing in this hollow body.
- Namie, a mystery female character that is not one of the previously introduced teen female characters.[24] Cebulski previously hinted that she does have ties to the Marvel Universe, eventually outed as a cyborg and the new model for the Red Ronin; UJ1-XD
- Spider-Woman (Mattie Franklin). After being exploited to create Mutant Growth Hormone, Mattie moved to Los Angeles to start over and has been going to meetings regularly, but left the team afterwards. Later, she was seen in New York City but was captured by Ana Kraven[25] and was later killed by Sasha Kraven.[26]
Within War of Kings: Darkhawk #1 are three former heroes that are seen among the Loners' support group, although they have not been identified.
Plot summary[edit]
The covers for each issue of the series are based on posters from 1980s teen films directed or written by John Hughes.[24]
Fear of Flying[edit]
- Issue One: The Breakfast Club[24]
The first issue opens with Julie Power apologizing to Phil Urich on her cell phone; Phil tries to convince her not to do anything rash but fails: Julie steps off a tall building, free falls, and then flies into the air. Shortly afterwards, both Phil and Mickey Musashi discuss Julie's actions and plan their next move.
The support group meets in the basement of a church,[27] and after waiting for Julie to arrive, decide to begin without her. Mattie Franklin is asked to speak first, recalling her experiences as Spider-Woman. Julie finally arrives at the tail-end of a cell phone conversation apparently with her brother Alex. She apologizes to the group for both her tardiness and her recent relapse.
Chris Powell insults Julie, who suggests that she has the hardest struggle of them all because she has had her powers the longest (seven years). Mattie, however, points out that although she has not been in the hero business as long as the rest of the group members, concealing her psionic spider-legs subjects her to constant physical pressure. After dramatically revealing her appendages, she storms out of the meeting.
Outside the church, Mattie explains to Chris that she has some unfinished business with MGH dealers,[28] who exploited her in the past; she has tracked them to Los Angeles. She asks that he assist her as Darkhawk for just one mission.
Darkhawk and Spider-Woman storm the MGH dealers' hideout and defeat the dealers easily, but they are attacked by the person "supplying the materials" for MGH, Nekra. Luckily, support group member Johnny Gallo (Ricochet) has followed Darkhawk and Spider-Woman to the dealers' base of operations and aids them in escaping Nekra's clutches. After defeating her, the trio discovers a list containing the names of supervillains being supplied MGH by the dealers and decides to investigate further, while agreeing not to tell the rest of the group.
Reflex Actions[edit]
- Issue Two: Ferris Bueller's Day Off[24]
A week later, Johnny contemplates what to do next. Later at a restaurant, Johnny tries to convince both Chris and Mattie to tell the rest of the support group about what they have done. Mattie insists that she needs more time to follow up on the information they have gathered. When Johnny sarcastically reminds Mattie of her "act" during the recent group meeting, she nearly attacks him and accuses him of attending the group for selfish reasons.
At the next support group meeting, Phil mentions the MGH bust and suggests that it could be used as an additional reason to further encourage teen superheroes to establish normal lives. Johnny gets up to speak, Mattie and Chris thinking he is about to reveal their recent actions. However, he tells the group about why he moved to Los Angeles. After the Slingers disbanded, his best friend Eddie McDonough (Hornet) convinced Johnny to continue as a superhero. Ricochet admits that he did so for the glory rather than to help people, but when Hornet was killed by Wolverine, Johnny blames himself for his friend's death, since he refused to help him prior to the situation.
Johnny unsuccessfully tries to contact both Mattie (who ignores his call while reading over some research about Ricochet's former teammates) and Chris (who arrives at Mickey's place to take her on a date). Ricochet heads to the deserted warehouse that is their main lead; he sneaks in and is shocked to see women held under sedation in fluid-filled containers. He is attacked by the Rose's former assassin Delilah, who assumes he is the same Ricochet who betrayed her in the past.[29]
Although Ricochet defeats her, during the course of the battle one of the containers is smashed and the former Generation X mutant known as Penance emerges.
What Lies Beneath[edit]
- Issue Three: Weird Science[24]
Phil Urich narrates events as the group meet in a local emergency room. He relates (through external analepsis) the tale of Johnny's fight with Penance and how it led to Julie being stabbed after flying into frame in the middle of Johnny and Penance's fight. (No explanation is given why Julie is suddenly present, though her immediate maiming at Penance's hands is most likely simply an instance of Women in Refrigerators syndrome, in order to give parallels to the violent death of Johnny Gallo's friend Hornet at the hands of Wolverine and thus give Johnny a reason to act. This graphic scene was also released in previews by Marvel to publicise the book.[30]) Suddenly remembering that he left Penance and several defenseless women back in the warehouse, Johnny runs out of the ER attempting to return to the scene, but he is stopped by accusations from the group about his behaviour. Penance appears before the group having somehow tracked Johnny, and invisible gun-toting soldiers suddenly attack, having somehow tracked Penance. There follows a brief battle which ends when Mickey appeals to the head of the opposing group as a fellow Japanese national and they negotiate a settlement in their "own language", the mysterious terms of which remain unknown to the group. The various members go their separate ways for the evening, and Penance returns home with Phil to sleep on his floor. Julie flies from the hospital before her parents can be contacted about her condition, and it becomes apparent Phil is somehow hallucinating that he sees the Green Goblin when he looks in the mirror.
What You Don't Know[edit]
- Issue Four: Pretty in Pink[24]
Julie and Johnny have lunch; he is astounded by her healing abilities caused by the Kymellian changes to her DNA, noting that she was stabbed in "the gut", despite her scar clearly being visible on her shoulder. Julie is intrigued by Hollow (formerly Penance) staying at Phil Urich's place, and fans the rumors about Mickey and Chris' romance. The two arrive at Marvel Studios to keep Julie's appointment for an audition.
At Phil's apartment, he does dishes and looks over at the sleeping Hollow. An image of her kissing him as the Green Goblin appears within a dinner plate, leading him to smash the plate and awaken Hollow; she does her best to comfort him.
At the audition, the director suggests Julie needs acting lessons; she leaves in a huff. She and Johnny criticize the director, who (they think) over-uses CGI effects. Another director named Mark Lowell overhears them and mentions the troubles he has in finding good stuntmen. Julie offers both her and Johnny's services, which pleases the director but creates doubts for Johnny — the two must use their powers to perform their new jobs.
At the James Dean Observatory;[31] Chris apologizes to Mickey. She admits that she dislikes having "other girls in the group". Chris asks why Mickey does not view Julie as a girl, and Mickey begins to respond that Julie "isn't--", but catches herself, mentioning that Julie is focused on her acting career and not "into the dating scene".
Julie, dressed as the Black Cat and Johnny, dressed as Iron Fist, perform stunts. The director expresses his satisfaction. His compliments lead Julie to fly off the set; Johnny contacts Mattie and tells her that they will have to reschedule their meeting. Julie apparently phones her sister Katie with her news. Back at Julie's dressing room, the director barges in and acts in an inappropriate manner, eventually physically accosting Julie. He threatens to report her unauthorized use of her powers when she throws him from the trailer. Julie counters that there are laws to protect minors against sexual predators. The director is shocked; he was unaware that Julie is only seventeen. Julie leaves the film set.
At the meeting, Julie speaks first. As Johnny did previously,[14] she admits to lying about her reasons for quitting superheroics. She hands out a photograph of Power Pack, suggesting that from early childhood she needed to learn to keep her powers and other information about her siblings secret (though in the original Power Pack series, it was Julie who most resisted hiding her powers, and in all other appearances as a member of Excelsior/Loners, she mentions her siblings frequently, and does not wear a mask to hide her identity, even though all the other members of the team do). She admits that a Hollywood career may not happen for her and resolves to be more honest.
Julie's final admission is interrupted by Nekra, who informs the group that she found them by using the information regarding their support group that they regularly release on the internet and to attack them.
Chinks in the Armor[edit]
- Issue Five: Some Kind of Wonderful[24]
The group is overwhelmed by Nekra. Phil and Mickey are powerless to stop the villain, and only the timely arrival of Namie ends the battle. Afterwards Phil learns of Chris and Mickey being a couple. At the same time, Mattie and Johnny go back to Johnny's apartment. While Johnny is taking a shower, Mattie investigates his place. Johnny catches her and Mattie seduces him in order to keep her cover. It is later revealed she was hired by the former Slinger Dusk's parents to locate their daughter. Meanwhile, Mickey confronts Chris about feeling helpless in the battle with Nekra, as well as for Chris not giving up the Darkhawk amulet. Mickey reveals she felt powerless without her armor and feels inadequate next to the rest of the group because they have 'real' powers — except for Chris, whose armor mirrors Mickey's own superhero abilities and identity. Their argument is put on hold when Phil arrives with Hollow, who has changed colour from the previous issue without explanation. Phil begins berating Mickey, then attacking Chris and stealing the amulet, in which he transforms into a Goblin-like version of Darkhawk.
Double Identities[edit]
- Issue Six: Sixteen Candles[24]
Chris is recovering from the attack, only to witness Phil in Darkhawk armor attacking Hollow and advancing on Mickey. Chris manages to tap into the amulet's power and becomes Darkhawk in his second armored form,[32] though it is not explained how he can utilise the armor without a whole amulet, as it has been previously established that without such an artifact, the Darkhawk armor remains inert. While the two battle, the other Loners, including an armored Mickey, arrive. Phil is defeated and Chris takes back the amulet. Phil then leaves the Loners, but not before revealing that Namie is a cyborg (the new Red Ronin), that Mickey made a secret bargain with Fuyumi Fujikawa, and that Julie is hiding a terrible secret from the group. Penance picks up Phil and they fly away unhindered, though the means of levitation and propulsion by which this is achieved are never explained. Disgusted, Mattie berates the group about their past decisions about not using their powers, as well as her choice of sleeping with Johnny, and leaves.
A week later, the Loners are back together minus Hollow, Phil, and Mattie. None of the subplots from the series bar the identity of Namie have been resolved, and the issue ends with no one willing to talk about their problems or what has so far happened.
After the series has ended, the group are next seen in the apartment of Mickey Musashi celebrating Christmas and attempting to solve some of their personal issues with each other through Secret Santa.[33]
The future[edit]
At the 2008 Wizard World: Philadelphia a question about a possible new Loners series was raised. C. B. Cebulski said there are plans for some of the characters in "different places" (see "War of Kings" note below), suggesting that it was "a tough market for a book like Loners",[34] though Marvel's overall sales figures were actually increasing at the time of Loners' publication,[35] with even the company's traditionally low-selling (via the direct market) 'All Ages' range slowly making gains at the same time Loners dropped several thousand readers.
Author Cebulski had Loners planned for eighteen issues but does not know if he would be allowed to go onto ongoing. He hopes to continue Loners and waits for Marvel's permission.[36] This seems deeply unlikely, however, as sales figures reveal Loners as selling 5000 copies less than Marvel's break-even point for ongoing titles towards the end of its run, despite initially good sales for early issues.[37]
With a follow-up series unlikely, Cebulski posted an apology to readers on Newsarama forums[38] that he did not "meet and match all your expectations for the characters", and that he would clarify continuity errors and unexplained events in a series post-mortem on that very site. Though he declined to answer questions that would have been answered in future issues of the book had they ever been commissioned or published.
Darkhawk later appeared in the pages of Nova as the head of security for Project Pegasus. He revealed that he had registered with the Initiative and that Justice had recommended him for the position.[39] Darkhawk is also a cast member within the War of Kings Event, with his own two issue miniseries in February and March 2009 tidying up continuity problems created by the unlikelihood of a sequel to Loners and freeing the character for use as the lead in Dan Abnett and Andy Lanning's four-part miniseries, War of Kings: Ascension. Though no longer associated with the Loners, Darkhawk's former teammates appear within both issues of his miniseries (though it remains unexplained how they - and the church in which they held their meetings - relocated from Los Angeles to New York), and it becomes apparent that Darkhawk left the team because he could no longer turn his back on his responsibilities as a superhero and wished to "focus (his) anger into something productive", creating friction with some members of the Loners. Though the group is hostile towards him, he makes amends with his former girlfriend Mickey Musashi/Turbo.[40] During the events of War of Kings: Ascension, it is revealed that Darkhawk is now 'the most wanted man in the galaxy' and will play a role in future issues of Nova - it seems unlikely he will rejoin the Loners in comic book limbo for the foreseeable future.
The remaining Loners (without Namie/Red Ronin, but with Penance/Hollow) are seen within the Avengers Academy series among the other various superpowered youths and young adults being offered additional training as part-time students, with Julie attending there as a full-time student and teacher's assistant.[21]
Other versions[edit]
In the alternate reality of the "Days of Future Now" storyline, the Excelsior team consists of Cecilia Reyes, Diamond Lil, Random, and Ricochet.
- ^ a b c d e Brian K. Vaughan (w), Adrian Alphona (p), David Newbold and Craig Yeung (i). "True Believers" Runaways v2, 1 (April 2005), Marvel Comics
- ^ "Loners".
- ^ Loners #1
- ^ Loners #3
- ^ a b Brian K. Vaughan (w), Adrian Alphona (p), David Newbold and Craig Yeung (i). "True Believers" Runaways v2, 6 (September 2005), Marvel Comics
- ^ Richard George. "IGN: Loners #1 Preview". IGN. Retrieved 2008-09-23.
- ^ Rich Johnston. "Lying in the Gutter". Comic Book Resources. Retrieved 2006-09-28.
- ^ Comic Book Urban Legends Revealed #158, Comic Book Resources, June 5, 2008
- ^ Marvel Team-Up Vol.3 #15
- ^ Runaways vol.2 #1-6
- ^ Power Pack vol.2 #1-4
- ^ Marvel Team-Up vol.3 #15
- ^ a b Runaways vol.2 #1
- ^ a b c Loners #2
- ^ Wolverine Vol.3 #20-32
- ^ a b Loners #4
- ^ Power Pack Vol.2 #4
- ^ Runaways Vol.2 #6
- ^ "IMPORTANT UPDATE FOR FANS.MARVEL.COM USERS - IMPORTANT UPDATE FOR FANS.MARVEL.COM USERS - Comics - Marvel.com".
- ^ Jesse Schedeen. "IGN: Marvel Holiday Special 2007 Review". IGN. Retrieved 2008-09-23.
- ^ a b c Avengers Academy #21
- ^ Amazing Spider-Man #648-50
- ^ Runaways (2nd series) #1
- ^ a b c d e f g h Newsarama. "A's FOR THE Q's: CEBULSKI TALKS LONERS". Newsarama. Archived from the original on 2009-03-02. Retrieved 2008-09-23.
- ^ In Amazing Spider-Man #611
- ^ Amazing Spider-Man #634
- ^ First seen in Runaways (vol 2) #1
- ^ From Alias #16-21
- ^ The Amazing Spider-Man #434-435
- ^ Richard George (3 May 2007). "Loners #3 Preview". IGN.
- ^ First seen in Runaways (vol. 1) #2
- ^ First seen in Darkhawk #38
- ^ Marvel Holiday Special 2007
- ^ Matthew Reichl. "WW PHILLY '08: Mondo Marvel Panel". Newsarama. Retrieved 2007-09-21.
- ^ "Page not found — The Beat". The Beat.
- ^ "Archived copy". Archived from the original on 2009-03-02. Retrieved 2008-09-23.
- ^ "July 2007 Sales Figures". New Warriors Continuity Conundrum.
- ^ http://forum.newsarama.com/showthread.php?t=137165&page=4
- ^ Nova vol.4 #17-19
- ^ War of Kings: Darkhawk #1-2