Method of fabricating an article with cavities

Abstract

An article having a cavity with a thin bottom wall is provided by assembling a thin sheet, for example, a metal sheet, adjacent to the surface of a member having one or more apertures. A bonding adhesive is interposed between the thin sheet and the subadjacent member, and the thin sheet is subjected to a high fluid pressure. In order to prevent the differential pressure from being exerted against the thin sheet, the aperture is filled with a plug of solid material having a linear coefficient of thermal expansion higher than that of the member. When the assembly is subjected to pressure, the material is heated to a temperature such that its expansion exerts a pressure against the thin sheet thus reducing the differential pressure.