Superplastic formed and diffusion bonded structures

A transport vehicle having at least one exterior panel, the at least one exterior panel comprising:

• an exterior skin configured for atmospheric exposure;
• an interior skin configured for attachment to a structural frame member of the transport vehicle;
• a multicellular core configured to impart tensile and compressive strength to the exterior panel, the multicellular core being sandwiched between the exterior skin and the interior skin;
• and
• at least one tube extending through the multicellular core, the tube being configured for conveyance of a cooling fluid,
• wherein the multicellular core is superplastic formed and diffusion bonded to the exterior skin, and the interior skin.

A method of manufacturing an exterior panel for a transport vehicle, the method comprising:

• providing an exterior skin of a superplastic material configured for atmospheric exposure;
• providing a tube to be fixed proximate to the exterior skin;
• providing an interior skin of a superplastic material configured for attachment to a structural frame member of the transport vehicle;
• providing at least one core sheet of a superplastic material for forming a multicellular core between the exterior skin and the interior skin;
• and
• installing the exterior skin and the interior skin with the at least the one core sheet layer into a pressure containment device, supplying an inert gas into an expansion pipe to superplastic form and diffusion bond the skins and layers, creating a multicellular core that is integrally bonded to the exterior skin, the tube, and the interior skin;
• wherein the tube extends through the exterior panel.