Method for forming and heat treating near net shape complex structures from sheet metal

A method of a complex-shaped metal part, the method comprising:

• enclosing a worksheet within a metallic sheath, wherein the workpiece is sheet metal made of at least one of a refractory alloy and a reactive alloy, wherein the metallic sheath is sacrificial metal;
• evacuating atmosphere through an opening of the metallic sheath via vacuum;
• sealing the opening of the metallic sheath following the evacuating step, wherein after the enclosing, evacuating, and sealing steps, the metallic sheath fully encases the worksheet and vacuum pressure in the metallic sheath draws the metallic sheath into close conformity with all sides of the worksheet;
• applying an electric current through the workpiece in the metallic sheath to heat the workpiece;
• shaping the workpiece in the metallic sheath into a complex-shaped metal part, including pressing the workpiece in the metallic sheath against at least one ceramic tooling surface;
• and
• cooling the complex-shaped metal part
• wherein the metallic sheath fully encases the worksheet and vacuum pressure in the metallic sheath draws the metallic sheath into close conformity with all sides of the worksheet before said shaping.