System and method for forming a metal component

Abstract

The present invention relates to systems and methods for forming metal components. In particular, a system and method for electroforming a metal component includes injecting an electrolytic solution from an injection manifold through a set of injection nozzles into a bath to define an electrolytic solution fluid flow within the bath, the electrolytic solution fluid flow extending from the injection manifold to an anode, to a cathode, and to a fluid outlet conduit.

Description

Technical Field

[0001] This disclosure generally relates to metallic components, and more specifically to systems and methods for electroformed metallic components. Background Technology

[0002] A turbine engine is a rotating engine that extracts energy from the flow of working air. The working air is sequentially passed through the compressor section, combustor section, and turbine section. The compressor section compresses the working air. The combustor section adds fuel to the pressurized air and ignites it. The turbine section expands and extracts work from the working air to drive the compressor section and other systems, and provides thrust. The compressor and turbine stages consist of pairs of rotating blades and stationary vanes arranged axially. The rotating blades are arranged circumferentially around the engine centerline.

[0003] The fan blades are exposed to the atmosphere in front of the engine and are susceptible to impact from birds or other foreign objects that may be sucked into the engine. For this reason, turbofan blades typically include metal components, such as blade guards, to reinforce the structure and protect the fan blades from impacts, such as bird strikes. These metal components can be formed using an electroforming process. Summary of the Invention

[0004] According to one aspect of this disclosure, a system for electroforming metal components is provided, comprising: a bath configured to contain an electrolyte solution, the bath having a fluid inlet pipe and a fluid outlet pipe fluidly connected to the electrolyte solution; a fluid pump connected in fluid communication to the fluid inlet pipe to provide the electrolyte solution thereto, and connected in fluid communication to the fluid outlet pipe to receive the electrolyte solution therefrom; an injection manifold connected in fluid communication to the fluid inlet pipe to receive the electrolyte solution therefrom, the injection manifold including a group of injection nozzles configured to inject the electrolyte solution therefrom into the bath to define an electrolyte solution fluid flow within the bath, the electrolyte solution fluid flow extending from the injection manifold to the fluid outlet pipe; an anode disposed in the bath downstream of the injection manifold relative to the electrolyte solution fluid flow; a cathode disposed in the bath downstream of the anode relative to the electrolyte solution fluid flow; and an electrical power supply electrically connected to the anode and cathode to provide current therebetween through the electrolyte solution in the bath.

[0005] According to another aspect of this disclosure, a method for electroforming a metal component is provided, the method comprising: disposing an electrolyte solution in a bath having a fluid inlet pipe and a fluid outlet pipe, the fluid inlet pipe and the fluid outlet pipe being fluidly connected to the electrolyte solution; immersing an injection manifold including a group of injection nozzles in the electrolyte solution in the bath; connecting the injection manifold to fluid communication with the fluid inlet pipe; connecting a fluid pump to fluid communication with the fluid outlet pipe to receive the electrolyte solution therefrom; connecting a fluid pump to fluid communication with the fluid inlet pipe to supply the electrolyte solution thereto; pumping the electrolyte solution from the fluid inlet pipe to the injection manifold; injecting the electrolyte solution from the injection manifold into the bath to define an electrolyte solution fluid flow within the bath, the electrolyte solution fluid flow extending from the injection manifold to the fluid outlet pipe; disposing an anode in the bath downstream of the injection manifold relative to the electrolyte solution fluid flow; disposing a cathode in the bath downstream of the anode relative to the electrolyte solution fluid flow; and electrically connecting a power supply to the anode and cathode to provide current therebetween via the electrolyte solution. Attached Figure Description

[0006] In the diagram: Figure 1 This is a schematic cross-sectional view of a turbine engine according to an exemplary aspect of this disclosure.

[0007] Figure 2A This is a schematic illustration of a system for forming a metal component according to an exemplary aspect of this disclosure.

[0008] Figure 2B It is along Figure 2A The cross section intercepted by line II-II.

[0009] Figure 3 This is a flowchart of a method for forming a metal component according to an exemplary aspect of this disclosure. Detailed Implementation

[0010] This disclosure relates to methods and systems for forming metal components. More specifically, this disclosure relates to methods and systems for electroforming metal components that provide improved wall thickness control and reduced porosity and pitting of the metal components compared to conventional methods and systems.

[0011] For illustrative purposes, the aspects of this disclosure discussed herein will describe fan blade shrouds for gas turbine engine fan blades. However, it will be understood that this disclosure is not limited thereto, but may have general applicability for electroforming any desired metal component for any desired application, including non-aircraft applications, such as other mobile applications, and non-mobile industrial, commercial, and residential applications, without departing from the scope of this disclosure.

[0012] Reference will now be made to various aspects in detail, one or more examples of which are illustrated in the accompanying drawings. Detailed descriptions use numbers and letters to denote features in the drawings.

[0013] The word "exemplary" is used in this document to mean "serving as an example, instance, or illustration." Any implementation described as "exemplary" in this document is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, unless otherwise specifically indicated, all aspects described herein should be considered exemplary.

[0014] As used in this text, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and, unless otherwise stated, are not intended to indicate the location or importance of a single component.

[0015] The singular forms “a,” “an,” and “the” include plural references unless the context clearly specifies otherwise. Furthermore, as used herein, the elements in the term “group” or “as a set” can be any number of elements, including a single element.

[0016] The term "fluid" can refer to a gas, a liquid, or multiple phases. The term "fluid connectivity" means that fluids can establish connections between specified areas.

[0017] As used in this text, the term "electrodeposition rate" refers to the rate at which metal ions are reduced and deposited onto the substrate. The electrodeposition rate in a system can be affected by many factors, including but not limited to the electric field strength in the electrolyte, the anode material, the cathode material, and the properties of the electrolyte, such as ion concentration, conductivity, resistivity, temperature, viscosity, pH level, chemical stability, additives, and impurities.

[0018] As used in this text, the term "monolithic monolithic body" or "monolithic body" means a single body that is a single, indivisible block, or formed as a single monolithic block during manufacturing, as opposed to being formed by combining separate components into one during manufacturing.

[0019] As used in the text, the term "upstream" refers to the direction opposite to the direction of fluid flow, while the term "downstream" refers to the direction in the same direction as the fluid flow.

[0020] The terms "front" or "front part" refer to what is in front of something, while "rear" or "rear" refer to what is behind something. For example, in the case of a turbocharged engine, "front" refers to the part closer to the engine inlet, while "rear" refers to the part closer to the engine nozzle or exhaust port.

[0021] Additionally, as used in this text, the term "radial" or "along the radial direction" refers to a dimension away from a common center. For example, in the context of a turbine engine, "radial" refers to the direction of a ray extending between the engine's central longitudinal axis and its outer circumference.

[0022] All directional references (e.g., radial, axial, proximal, distal, up, down, upward, downward, left, right, lateral, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, front, rear, etc.) are used for identification purposes only to assist the reader in understanding this disclosure and do not constitute a limitation, particularly with respect to the location, orientation, or purpose of aspects of this disclosure described herein.

[0023] Connection references (e.g., attachments, joins, connections, and links) should be interpreted broadly and, unless otherwise indicated, may include intermediate structural elements located among a group of elements and relative movement between elements. Therefore, a connection reference does not necessarily imply that two elements are directly connected and in a fixed relationship. Exemplary figures are for illustrative purposes only, and the dimensions, positions, orders, and relative sizes reflected in the figures attached herein may vary.

[0024] Conventional gas turbine engines may include fan sections with airfoils. For example, an airfoil may include fan blades and / or outlet guide vanes. Conventional fan blades are typically made of low-density metals (such as aluminum) or composite materials to reduce their weight.

[0025] During the operation of a gas turbine engine (e.g., during flight), foreign objects can become trapped in the engine inlet and impact the fan blades, causing damage. Foreign objects can include birds, rainwater, hail, ice, or other debris. Impact from a relatively large object (e.g., a bird) can tear the blades, causing blade fragments to fly radially outward at high speed. Conversely, impacts from relatively small foreign objects (e.g., grains of sand) can gradually erode the blades.

[0026] One known solution to reduce damage to fan blades from impacts by foreign objects is to attach appropriate metal edge guards or shrouds to the leading edge of each fan blade. Fan blade shrouds, sometimes called metal leading edge (MLE) shrouds, help provide erosion or impact protection to the fan blades, particularly their leading edges. Fan blade shrouds also allow impact energy to be transferred through the shroud to a larger area than the point of impact.

[0027] Conventional fan blade shrouds are typically formed, at least in part, of materials comprising metallic alloys. For example, fan blade shrouds may be formed of materials such as titanium and nickel metals or alloys thereof. These metallic materials possess enhanced physical properties, including toughness, flexural modulus, bulk modulus, hardness, elasticity, or ductility, and combinations thereof, which can provide better strength and ductility compared to the low-density metals or composite materials used to form the fan blades themselves. These enhanced material properties of fan blade shrouds typically provide enhanced energy absorption in the event of impacts from airborne debris.

[0028] Titanium alloys offer a high strength-to-weight ratio, good temperature and chemical resistance, and relatively low density, making them ideal for use as fan blade shrouds. However, titanium alloys are extremely difficult to machine using conventional grinding tools, and the associated costs are high due to their short tool life. One known solution to the high machining costs is to fabricate fan blade shrouds using an electroforming process.

[0029] In a conventional electroforming process, the cathode (e.g., a negatively charged electrode), in the form of a mandrel or an article to be electroplated as a substrate, is immersed in a suitable electrolyte solution, and an electric current (e.g., an electroplating current) is transferred through the electrolyte solution located between a suitable anode (e.g., a positively charged electrode) and the cathode. The electrolyte solution typically contains one or more metal salts, such as copper sulfate, to facilitate the passage of the current. The current transfer through the electrolyte solution causes the article to be electroformed onto the cathode with the desired metallic or alloy finish. The anode and cathode are disposed in the electrolyte solution and electrically connected to a power supply (or power source) that creates an electric field in the electrolyte solution between the anode and cathode and supplies a direct current (DC) current to the anode. This current causes the metal to oxidize, allowing metal atoms at the anode to dissolve in the electrolyte solution as positive metal ions. The current then causes the metal ions to move from the positively charged anode to the negatively charged cathode and deposit as a thin metal layer onto the mandrel or cathode.

[0030] Typically, the anode has the same general composition as the metal (e.g., titanium) or alloy to be deposited on the mandrel. The anode material dissolves through electrochemical action to continuously replenish the metal content of the electrolyte solution consumed by electroplating or forming on the workpiece. The anode material typically provides a dual function: simultaneously completing the circuit between the anode and cathode, and replenishing the metal content of the electrolyte solution.

[0031] Typically, a composite structure (often called a "basket") that is conductive but chemically inert relative to the electrolyte solution is used to support or contain the anode material. The anode material can be formed in relatively small pieces (sometimes called coins or blanks, etc.) arranged in electrical contact with each other and with the conductive anode basket. The anode basket is typically suspended in the electrolyte solution from conductive support rods or other support structures. The electrolyte solution is in fluid communication with the anode material contained therein by providing openings in the anode basket. In operation, the anode material can be gradually consumed and replaced as needed at appropriate intervals.

[0032] For example, in a specific example of a fan blade shroud to be formed by a conventional electroforming process, the mold or mandrel may have an outer surface made of a conductive material, such as titanium. The outer surface of the mandrel may correspond to the airfoil configuration of the fan blade minus the thickness of the fan blade shroud to be electroformed onto the mandrel. The desired thickness of the fan blade shroud can also be obtained using a well-known “shrouding” process, in which a non-conductive barrier wall or “cathode shroud” is placed adjacent to the mandrel to influence or guide current through the electrolyte solution between the anode and cathode. After the mandrel is retained in the electrolyte solution under the influence of an electric field for a predetermined period of time, it is removed. The material electrodeposited on the outer surface of the mandrel is mechanically removed from the mandrel as a new electroformed fan blade shroud. The fan blade shroud can then be machined in a manner well known in the art to smoothly fit onto the corresponding fan blade.

[0033] However, conventional fan blade shrouds for gas turbine engines are typically limited by a thickness range ratio, defined by the ratio of the thickness of the thickest part of the shroud (e.g., the leading edge) to the thickness of the thinnest part (e.g., the trailing edge), generally 5:1, and can reach 10:1 at higher costs. However, the increased strength requirements for modern fan blades may necessitate a ratio as high as, for example, 80:1. These requirements demand precise tolerances and electroplating uniformity, and therefore pose challenges to electroformed fan blade shrouds.

[0034] For example, a problem with conventional electroforming methods is that, in many cases, during operation, as individual anode material pieces gradually decrease in size over time, voids are created in the anode material due to bridging of these individual anode pieces. This bridging prevents the anode material from settling to the bottom of the anode basket as it is consumed, and thus prevents sufficient space from forming to add new anode material to the basket. Bridging also causes the amount of anode material in contact with the electrolyte to vary over time, resulting in poor uniformity of the deposited material and increased porosity or pitting on the electroformed surface.

[0035] One known solution to overcome anode bridging is to agitate the anode basket so that the anode material settles to the bottom, allowing for proper refilling of the basket. Typically, agitating the anode basket to settle the anode material is done either manually (e.g., by shaking the basket) or by using a mechanical or motorized mechanism to shake or bump the basket to cause the anode material to settle. Such techniques and / or mechanisms can add extra costs and, in some cases, may cause damage to the basket.

[0036] In addition, while conventional cathode shields placed between the anode and cathode can help influence or guide the current from the anode and cathode through the electrolyte, they can also cause uneven flow of ions through the electrolyte, resulting in uneven deposition of anode material onto the cathode.

[0037] To better address the challenges posed by the gas turbine industry's demand for tight tolerances in electroformed metal components to produce reliable and high-performance gas turbines, it is therefore desirable to provide an improved system and method for electroforming fan blade shrouds with improved operating efficiency and reasonable cost. Advantageously, the aspects disclosed herein provide an electroforming system comprising a fluid pump and an injection manifold including a group of nozzles arranged to cooperatively inject an electrolytic fluid flow from the anode toward the cathode, advantageously achieving a controlled ion flow through the electrolyte solution and further achieving improved control over the thickness of the electroformed metal component compared to conventional techniques. Furthermore, the electrolyte solution can be agitated, removed, or otherwise removed to eliminate bubbles (e.g., hydrogen) that may form on the cathode surface during electroforming operations, advantageously achieving reduced pitting and porosity of the metal component compared to conventional methods. The reduced porosity provided by the aspects disclosed herein can enhance the aerodynamic performance of the metal component when used as a fan blade shroud. Additionally, the aspects disclosed herein can reduce anode bridging without the need for mechanical agitators.

[0038] Figure 1 This is a schematic cross-sectional view of a gas turbine engine 10 for use in an aircraft. The gas turbine engine 10 has a generally longitudinally extending axis, or engine centerline 12, which extends from the front 14 to the rear 16. The gas turbine engine 10 includes, in downstream series flow relationships, a fan section 18 (including a fan 20), a compressor section 22 (including a turbocharger or low-pressure (LP) compressor 24 and a high-pressure (HP) compressor 26), a combustion section 28 (including a combustor 30), a turbine section 32 (including an HP turbine 34 and an LP turbine 36), and an exhaust section 38.

[0039] Fan section 18 includes a fan housing 40 surrounding fan 20. Fan 20 includes a plurality of fan blades 42 arranged radially around engine centerline 12. Fan 20 can have any suitable configuration, such as a variable pitch single-stage configuration. Fan blades 42 can be coupled to fan disk 41 in a circumferentially spaced manner. Fan blades 42 can extend generally radially outward from fan disk 41. Fan blades 42 can be at least partially formed of composite materials (such as carbon fiber materials). Alternatively, or in an alternative, fan blades 42 can be at least partially formed of a metal alloy.

[0040] The fan blade 42 incorporates an airfoil adapted for efficient air movement and has a leading edge 43a and a trailing edge 43b. The fan blade 42 may include a hub end 42a attached to the fan disk 41 and a distal end 42b remote from the hub end 42a. Furthermore, the fan blade 42 may have a corresponding fan blade shroud 37 extending along the leading edge 43a of the fan blade 42 from the distal end 42b to the hub end 42a. Note that the fan blade shroud 37 is curved and has a twist from the distal end 42b to the hub end 42a, matching the geometry of the leading edge 43a of the fan blade 42. The fan blade shroud 37 may be attached to at least a portion of the leading edge of the fan blade 42.

[0041] The fan blade shroud 37 provides protection against damage such as from impacts and corrosion. The fan blade shroud 37 can be formed, at least in part, using additive manufacturing techniques and any suitable metallic alloy or non-metallic material (such as those described herein). In a non-limiting aspect, the fan blade shroud 37 can have a monolithic structure.

[0042] The fan inlet 83 of fan section 18 is defined at the upstream end or front end 14 of the gas turbine engine 10. The fan exhaust port 84 is defined at the downstream end of the fan housing 40. The HP compressor 26, combustor 30, and HP turbine 34 form the engine core 44 of the gas turbine engine 10, which generates combustion gases. The engine core 44 is surrounded by a core housing 46, which can be coupled to the fan housing 40.

[0043] The HP shaft or shaft 48 is coaxially arranged around the engine centerline 12 of the gas turbine engine 10, drivingly connecting the HP turbine 34 to the HP compressor 26. The LP shaft or shaft 50 is coaxially arranged within a larger diameter annular HP shaft 48 around the engine centerline 12 of the gas turbine engine 10, drivingly connecting the LP turbine 36 to the LP compressor 24 and the fan 20. The shafts 48 and 50 are rotatable around the engine centerline 12 and are coupled to multiple rotatable elements, which together define the rotor 51.

[0044] LP compressor 24 and HP compressor 26 each include multiple compressor stages 52 and 54, respectively, in which groups of compressor blades 56 and 58 rotate relative to corresponding groups of static compressor vanes 60 and 62 (also referred to as nozzles) to compress or pressurize the fluid flow passing through the stage. In a single compressor stage 52 or 54, the multiple compressor blades 56 and 58 may be arranged in a ring and may extend radially outward relative to the engine centerline 12, from the blade platform to the blade tip, while the corresponding compressor vanes 60 and 62 are positioned upstream of and adjacent to the rotating blades 56 and 58. Note that the selection... Figure 1 The numbers of blades, vanes, and compressor stages shown are for illustrative purposes only, and other numbers are also possible.

[0045] Blades 56 and 58 for the compressor stages can be mounted to a compressor disk 61, which is mounted to a corresponding one of the HP and LP shafts 48 and 50, with each stage having its own compressor disk 61. Blades 56 and 58 may be part of an integral bladed disk rather than mounted to a disk. Blades 60 and 62 for the compressor stages can be circumferentially arranged and mounted to the core housing 46.

[0046] HP turbine 34 and LP turbine 36 each comprise multiple turbine stages 64 and 66, wherein groups of turbine blades 68 and 70 rotate relative to corresponding nozzles 73 and 75, which include corresponding groups of static turbine vanes 72 and 74 to extract energy from the fluid flow transmitted through the turbine stages 64 and 66. In a single turbine stage 64 and 66, the multiple turbine blades 68 and 70 may be arranged in a ring and may extend radially outward relative to the engine centerline 12, from the blade platform to the blade tip, while the corresponding turbine vanes 72 and 74 are positioned upstream of and adjacent to the rotating turbine blades 68 and 70. The turbine blades 68 and 70 and the turbine vanes 72 and 74 may be airfoil-shaped. Note that the selection... Figure 1 The number of blades, vanes, and turbine stages shown is for illustrative purposes only, and other numbers are also possible.

[0047] The turbine stage blades 68 and 70 can be mounted to a turbine disk 71, which is mounted to a corresponding one of the HP and LP shafts 48 and 50, with each stage having a dedicated turbine disk 71. The turbine stage vanes 72 and 74 can be circumferentially arranged and mounted to the core housing 46.

[0048] Complementing the rotor section, the stationary parts of the gas turbine engine 10, such as the vanes 60, 62, 72, and 74 in the compressor and turbine sections 22 and 32, are also referred to individually or collectively as the stator 63. Therefore, the stator 63 can refer to the combination of non-rotating elements in the entire gas turbine engine 10.

[0049] In operation, the airflow leaving fan section 18 is split so that a portion of the airflow is directed into LP compressor 24, which then supplies pressurized airflow 76 to HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from HP compressor 26 mixes with fuel in combustor 30 and ignites, generating combustion gases. Some work is extracted from these gases by HP turbine 34, which drives HP compressor 26. The combustion gases are discharged into LP turbine 36, which extracts additional work to drive LP compressor 24, and the exhaust gases are ultimately discharged from gas turbine engine 10 via exhaust section 38. The drive of LP turbine 36 drives LP shaft 50 to rotate fan 20 and LP compressor 24.

[0050] A portion of the airflow leaving the fan section, referred to as bypass airflow 78, bypasses the LP compressor 24 and engine core 44, and exits the gas turbine engine 10 through a row of stationary airfoils, and more specifically through the outlet guide vane assembly 80 (comprising multiple airfoil guide vanes 82) at the fan exhaust port 84. More specifically, adjacent to the fan section 18, radially extended airfoil guide vanes 82 arranged in a circumferential row are used to exert some directional control on the bypass airflow 78.

[0051] Some of the air supplied by fan 20 can bypass engine core 44 and be used to cool portions of gas turbine engine 10, particularly hot portions, and / or to cool or power other aspects of the aircraft. In the context of a turbine engine, the hot portions of the engine are typically located downstream of combustor 30, particularly turbine section 32, which is directly downstream of combustion section 28. Other sources of cooling fluid may be, but are not limited to, fluid discharged from LP compressor 24 or HP compressor 26.

[0052] Figure 2A A block diagram depicting a non-limiting aspect of a system 110 for performing an electroforming process to form a metal component 138 as disclosed herein is provided. System 110 may include an electrodeposition bath 140 having a tank 145 containing an electrolyte solution 148. The electrolyte solution 148 is conductive. The tank 145 may include a fluid inlet conduit 141 and a fluid outlet conduit 142. System 110 may also include an injection manifold 150 defining a group of openings or injection nozzles 159. As shown, an anode material 160a ( Figure 2BThe anode 160, cathode 180, and injection manifold 150 (shown in the diagram) can be immersed in or disposed in the electrolyte solution 148. The anode 160 is spaced apart from the cathode 180. In a non-limiting aspect, a cathode shield 170 can be disposed between and spaced apart from the anode 160 and cathode 180. For example, the anode 160 is disposed between the injection manifold 150 and the cathode shield 170. Any number of mechanical supports, brackets, or hangers 146 can be used to position the injection manifold 150, anode 160, cathode shield 170, and cathode 180 in the bath 145 as needed. The system 110 may also include a fluid pump 147. An electrical power supply 190 (e.g., a DC power supply) can be disposed outside the bath 145 and electrically connected to the anode 160 and cathode 180.

[0053] Bath 145 contains an electrolyte solution 148. In a non-limiting aspect, the electrolyte solution 148 may comprise an aluminum alloy that carries alloy metal ions. In another non-limiting example, the electrolyte solution 148 may comprise a nickel alloy that carries alloy metal ions. In a non-limiting aspect, bath 145 may be made of a suitable acid-resistant material, such as polyethylene, polypropylene, or a fluoropolymer (e.g., Teflon). ® Or polyvinylidene fluoride (PVDF).

[0054] Fluid pump 147 is fluidly connected to fluid inlet pipe 141 and fluid outlet pipe 142 to arrange an electrolytic fluid flow (indicated by a series of arrows "149") of electrolyte solution 148 within bath 145. Fluid inlet pipe 141 is connected in fluid communication with injection manifold 150 to supply electrolyte solution 148 thereto. Fluid outlet pipe 142 is arranged in fluid communication with the electrolyte solution 148 disposed in bath 145 to receive the electrolytic fluid flow 149 therefrom.

[0055] In a non-limiting aspect, fluid inlet conduit 141 is disposed at a first end (e.g., bottom) of bath 145, and fluid outlet conduit 142 is disposed at the opposite second end (e.g., top) of bath 145. For example, as shown, fluid inlet conduit 141 may be located in the lower portion of bath 145, below anode 160, and fluid outlet conduit 142 may be located in the upper portion of bath 145, above cathode 180. It is contemplated that other aspects are not limited thereto, and fluid inlet conduit 141 and fluid outlet conduit 142 may be arranged or oriented relative to each other in various ways as needed, so that electrolytic fluid flow 149 can flow from upstream to downstream, from fluid inlet conduit 141 to injection manifold 150, to anode 160, to cathode shroud 170, to cathode 180, and to fluid outlet conduit 142. In some non-limiting aspects, for example, the orientation of the anode 160 and cathode 180 within the bath 145 can be reversed (e.g., where the anode 160 is oriented at the second end (e.g., the top) of the bath 145, while the cathode 180 is oriented at the first end (e.g., the bottom) and the electrolytic fluid flow 149 is arranged to flow from the second end of the bath 145 toward the first end of the bath 145). In other non-limiting aspects, for example, the anode 160 and cathode 180 can be arranged vertically and spaced apart from each other (e.g., from left to right or vice versa), where the electrolytic fluid flow 149 is arranged to flow horizontally within the bath 145.

[0056] Fluid pump 147 can allow electrolyte solution 148 to circulate or recirculate through bath 145 via fluid inlet pipe 141 and fluid outlet pipe 142. In some non-limiting aspects, filter 143 may optionally be provided to filter electrolyte solution 148 and chemically maintain it at a specific ion concentration, or to remove any foreign matter. As a non-limiting example, filter 143 may include a chemical filter medium. Optionally, heater 144 may be provided to regulate the temperature of electrolyte solution 148 in bath 145. In a non-limiting example, heater 144 may be disposed within bath 145 or externally near bath 145. Alternatively, heater 144 may be in fluid communication with fluid pump 147 to heat electrolyte solution 148 as it is pumped by fluid pump 147.

[0057] An electrical power supply 190, which may include a controller (not shown), may be electrically connected to an anode 160 and a cathode 180 via an electrical conduit 191 to form a circuit 192 via an electrolyte solution 148. The electrical power supply 190 may operatively create an electric field 193 across the electrolyte solution 148 between the anode 160 and the cathode 180. Optionally, a switch (not shown) or sub-controller may be included along the electrical conduit 191 and may be positioned between the electrical power supply 190 and the anode 160 and cathode 180. The electrical power supply 190 may be configured to provide a current 195 (as indicated by the dashed arrow) (e.g., electroplating current) to the anode 160, which may flow from the anode 160 to the cathode 180 via the electrolyte solution 148. The current 195 may cause metal ions to move from the anode 160 to the cathode 180 and deposit thereon.

[0058] Figure 2B Depicting along Figure 2A The image shows a cross-section of system 110 taken by line II-II, with some portions omitted for clarity. The injection manifold 150 may include at least one wall 150a arranged to define a manifold interior 158. This at least one wall 150a may also define a group of injection nozzles 159 passing through it. Thus, the manifold interior 158 defines a passage for an electrolytic fluid flow 149, which is in fluid communication with the group of injection nozzles 159. The injection manifold 150 is connected in fluid communication to a fluid inlet conduit 141. Figure 2A ), so as to receive the electrolytic fluid flow 149 therefrom. In this way, the electrolytic fluid flow 149 can be arranged to flow from upstream to downstream, from the fluid inlet pipe 141 to the injection manifold 150, and then radially outward through the group of injection nozzles 159 into the bath 145 toward the anode 160.

[0059] Anode 160 can be a sacrificial anode or an inert anode. Although only one anode 160 is shown, it should be understood that the bath 145 can include any number of anodes 160 as needed. Anodes 160 can be arranged as a defined container, or anode basket 165. Anode material 160a can be supported by or contained within the anode basket 165. In some aspects, anode material 160a can be in the form of groups of spheres, particles, disks, cubes, sheets, or any other desired geometry (including amorphous), but is not limited thereto.

[0060] The anode basket 165 may be formed of a conductive metal (e.g., titanium) that is insoluble in the electrolyte solution 148 and capable of maintaining a positive voltage potential to allow metal ions to be released from the anode material 160a contained therein. In a non-limiting aspect, the anode basket 165 may include a group of walls 164 arranged to define a basket interior 167 therebetween. For example, each wall 164 may have a first inward facing surface 164a facing the basket interior 167 and a opposing outward facing surface 164b facing the exterior of the anode basket 165. The anode basket 165 may also include a base plate or bottom 166. The bottom 166 may define a group of first orifices 166a through which the group of first orifices 166a is arranged to allow an electrolyte flow 149 to flow from the exterior of the anode basket 165 into the basket interior 167 and through or across the anode material 160a. In some aspects, the bottom 166 may also provide or define a support surface for the anode material 160a. The first orifice 166a can be smaller than the anode material 160a to prevent the anode material 160a from flowing into the first orifice 166a. Although the first orifice 166a is... Figure 2B The examples shown are generally cylindrical and have substantially the same size and orientation as each other, but other aspects are not limited thereto. It is contemplated that, in other respects, the size, shape, and relative orientation of the first orifice 166a may be selectively configured to influence any desired properties or characteristics of the electrolyzer flow 149, including, for example, the velocity and direction of the electrolyzer flow 149, without departing from the scope of this disclosure.

[0061] In a non-limiting aspect, the anode basket 165 may also include a top plate or cover 169. The cover 169 may define a group of second orifices 169a passing through it, the group of second orifices 169a being arranged to allow an electrolytic fluid flow 149 to flow through it from the basket interior 167 to the exterior of the anode basket 165. Although the second orifices 169a are... Figure 2B The examples shown are generally cylindrical and have substantially the same size and orientation as each other, but other aspects are not limited to this. It is contemplated that, in other respects, the size, shape, and relative orientation of the second orifice 169a may be selectively configured to influence any desired properties or characteristics of the electrolyte flow 149, including, for example, the velocity and direction of the electrolyte flow 149, without departing from the scope of this disclosure. It is further contemplated that, in other respects, the cap 169 may be omitted, such that the anode basket 165 has an open top. In some respects, one or more walls 164 may define corresponding groups of third orifices 164c therethrough to allow the electrolyte solution 148 to flow in or out, or both.

[0062] A cathode shroud 170 is disposed in a bath 145 between an anode 160 and a cathode 180. The cathode shroud 170 may define a cathode shroud body 171. In a non-limiting aspect, the cathode shroud body 171 may define a group of cathode shroud orifices 176 passing through it. The cathode shroud orifices 176 may be sized and oriented to receive an electrolyzer fluid flow 149 therethrough. It is contemplated that, in various respects, the cathode shroud 170 may define any desired number of cathode shroud orifices 176. The cathode shroud orifices 176 may be axially spaced apart from each other along the length of the cathode shroud 170. For example, in a non-limiting aspect, the cathode shroud orifices 176 may be spaced apart in rows along the axial length of the cathode shroud 170. At least a subgroup of the group of cathode shroud orifices 176 may be aligned with the cathode 180 (e.g., relative to the direction of the electrolyzer fluid flow 149). The group of cathode shroud orifices 176 can be customized in size and arrangement to control, guide or direct the speed or direction of the electrolytic fluid flow 149, or both.

[0063] The cathode shield 170 may be formed of a non-conductive or ion-resistive material. In a non-limiting aspect, the cathode shield 170 may be formed of a dielectric material, including but not limited to polymers, glass, and ceramics. For example, the cathode shield 170 may be made of polyethylene, polypropylene, or fluoropolymers (e.g., Teflon). ® It is made of materials such as PVDF.

[0064] In a non-limiting aspect, the cathode 180 may include a mandrel 182. The mandrel 182 may include an outer metal layer 183 (e.g., an outer coating). For example, in a non-limiting aspect, the outer metal layer 183 may be formed of copper, silver, or nickel, but is not limited thereto. It is contemplated that the outer metal layer 183 may be formed on the mandrel 182 via sputtering, spraying, coating, or similar processes to facilitate the formation of the cathode 180.

[0065] Mandrel 182 can be formed (e.g., by molding, machining, additive manufacturing, etc.) into a shape corresponding to the desired shape of metal component 138. Mandrel 182 includes a mandrel body 185, which, as a non-limiting example, is formed from a recyclable material. For example, mandrel body 185 can be made from a recyclable material that can be collected after an electroforming process and reused as another body in another electroforming process. Suitable recyclable materials can include wax, plastics, polymer foams, metals, or deformable materials, such as those that can be collected via melting or leaching in the non-limiting example. After the electroforming process is completed, mandrel body 185 can be recycled from the electroformed component, such as by heating and melting mandrel body 185 at elevated temperatures to recover structural material.

[0066] In operation, the bath 145 may contain a suitable amount or level of electrolyte solution 148, sufficient to cover or submerge the injection manifold 150, anode basket 165, and cathode 180. A fluid pump 147 may be operated to allow the electrolyte solution 148 to flow through the bath 145 from fluid inlet conduit 141 to fluid outlet conduit 142. The electrolyte solution 148 flows into the injection manifold 150 and is injected from a group of injection nozzles 159 toward the anode 160 to define an electrolytic fluid flow 149. The electrolytic fluid flow 149 may flow through a first orifice 166a and through gaps or spaces defined between and around the anode material 160a contained in the anode basket 165. In a non-limiting aspect, the electrolytic fluid flow 149 may then flow from the anode 160 toward the cathode shroud 170. The cathode shield 170 can partially block, impede, or change the direction of a portion of the electrolytic fluid flow 149, while allowing another portion of the electrolytic fluid flow 149 to flow around the cathode shield body 171 and / or through a group of cathode shield orifices 176 defined therethrough, toward the cathode 180.

[0067] The power supply 190 can operatively create an electric field 193 across the electrolyte solution 148 between the anode 160 and the cathode 180. The electric field 193 can cause a current 195 to flow through the electrolyte solution 148 from the anode 160 to the cathode 180. The current 195 can cause metal ions from the anode material 160a (e.g., tungsten) to move from the anode 160 to the cathode 180 and deposit onto the mandrel 182 to form a metal member 138. In a non-limiting example, the metal member 138 can be a fan blade shroud 37.

[0068] The electrodeposition rate of the anode material 160a at a specific region of the cathode 180 will depend in part on a variety of factors, including the characteristics of the electrolyte flow 149, the electric field 193, the current 195 through the electrolyte 148 between the anode 160 and the cathode 180, and the characteristics of the electrolyte flow 149 at any given point or region on the cathode 180. For example, in a non-limiting aspect, the profile of electrodeposited metal ions on the mandrel 182 can be selectively controlled, at least in part, by constructing the size, shape, orientation, and combination thereof of the cathode shield 170 and the cathode shield orifice 176 to adjust the electric field 193 or guide the electrolyte flow 149, or both, or a combination thereof.

[0069] The cathode shield 170 can be arranged and configured to shield predetermined points or portions of the surface of the cathode 180 from the current 195 and / or the electrolytic fluid flow 149. For example, since the cathode shield 170 is non-conductive (e.g., formed of a dielectric material), the strength of the electric field 193 between each given point on the anode 160 and the cathode 180 can be selectively altered or adjusted by the presence of the cathode shield 170. Furthermore, the shape, size, and position of the cathode shield body 171 within the electrolytic fluid flow 149, as well as the size, number, and position of the cathode shield orifices 176, can affect the characteristics (e.g., velocity and direction) of the electrolytic fluid flow 149 relative to the cathode 180.

[0070] It is anticipated that the outer region of the cathode 180 with an unshielded (e.g., unshielded by the cathode shroud 170) surface area will experience a relatively higher charge transfer rate compared to the outer region of the cathode 180 with a shielded (e.g., shielded by the cathode shroud 170) surface area. Therefore, by appropriately customizing the shape of the cathode shroud 170 and configuring the cathode shroud orifice 176 to arrange the desired characteristics (e.g., velocity and direction) of the electrolyte flow 149, the electrodeposition rate (and thus the thickness distribution of the electrodeposited metal) can be controlled.

[0071] Alternatively or concurrently, in a non-limiting aspect, the characteristics of the electrolytic fluid flow 149 can be controlled by adjusting the speed or direction of the electrolytic fluid flow 149, or both. For example, in a non-limiting aspect, the fluid pump 147 can be configured to increase or decrease the speed of the electrolytic fluid flow 149 in the fluid inlet conduit 141 or the injection manifold 150, or both. In some non-limiting aspects, the speed or direction of the electrolytic fluid flow 149 through the bath 145, or both, can be further controlled by configuring a group of injection nozzles 159 as needed.

[0072] Of course, the actual thickness distribution of the electrodeposited metal will also depend on various parameters used in the electroplating process (e.g., the metal used, the applied voltage and current, the concentration, temperature, flow rate, and type of additives and components in the bath 145).

[0073] Figure 3 A method 300 for forming a metal component 138 is shown. Unless otherwise stated, method 300 is provided for illustrative purposes and may be performed in a different logical order, or may include additional or intermediate steps. Although method 300 is... Figure 2A-2B The system 110 described in the background is as follows, but in order to form a metal component 138 by electrodeposition onto a mandrel 182, method 300 can be used in a similar manner to form other suitable forms to form other types of bodies.

[0074] Method 300 begins at 310 by placing an electrolyte solution 148 into a bath 145 having a fluid inlet pipe 141 and a fluid outlet pipe 142, which are fluidly connected to the electrolyte solution 148.

[0075] In a non-limiting aspect, the electrolyte 148 may comprise an aluminum alloy that carries alloy metal ions. In another non-limiting example, the electrolyte 148 may comprise a nickel alloy that carries alloy metal ions. In a non-limiting aspect, the bath 145 may be made of a suitable acid-resistant material, such as polyethylene, polypropylene, or a fluoropolymer (e.g., Teflon). ® Or PVDF).

[0076] Method 300 may include, at 315, immersing an injection manifold 150, including a group of injection nozzles 159, in an electrolyte solution 148 within a bath 145. In a non-limiting aspect, the injection manifold 150 may include a body having at least one wall 150a arranged to define a manifold interior 158. This at least one wall 150a may further define a group of openings or injection nozzles 159 passing through it. In a non-limiting aspect, the manifold interior 158 may define a channel for a fluid flow of electrolyte solution 149, which is in fluid communication with the group of injection nozzles 159.

[0077] Method 300 may include at 320 fluidly connecting the injection manifold 150 to the fluid inlet pipe 141; and at 325 connecting the fluid pump 147 to the fluid outlet pipe 142 to receive the electrolyte solution 148 therefrom.

[0078] Method 300 may further include, at 330, connecting the fluid pump 147 in fluid communication to the fluid inlet pipe 141 to supply the electrolyte solution 148 thereto. In some non-limiting aspects, a filter 143 may optionally be provided to filter the electrolyte solution 148 and chemically maintain it at a specific ion concentration, or to remove any foreign matter. As a non-limiting example, the filter 143 may include a chemical filter medium. Optionally, a heater 144 may be provided to regulate the temperature of the electrolyte solution 148 in the bath 145. In a non-limiting example, the heater 144 may be disposed within the bath 145 or disposed externally to the bath 145 near the bath 145. Alternatively, the heater 144 may be in fluid communication with the fluid pump 147 to heat the electrolyte solution 148 as it is pumped by the fluid pump 147.

[0079] Method 300 may include, at 335, fluidly pumping the electrolyte solution 148 from the fluid inlet pipe 141 to the injection manifold 150. Method 300 may also include, at 340, injecting the electrolyte solution 148 from the injection manifold 150 into the bath 145 to define an electrolytic fluid flow 149 within the bath 145, the electrolytic fluid flow 149 extending from the injection manifold 150 to the fluid outlet pipe 142. In a non-limiting aspect, the electrolytic fluid flow 149 may be arranged to flow from upstream to downstream, from the fluid inlet pipe 141 to the injection manifold 150, and then radially outward through a group of injection nozzles 159 into the bath 145 toward the anode 160. For example, in a non-limiting aspect, the fluid inlet conduit 141 and the fluid outlet conduit 142 may be arranged or oriented relative to each other in various ways as needed, so that the electrolytic fluid flow 149 can flow from upstream to downstream, from the fluid inlet conduit 141 to the injection manifold 150, to the anode 160, to the cathode 180, and to the fluid outlet conduit 142.

[0080] Method 300 may include, at 345, positioning an anode 160 in a bath 145 downstream of an injection manifold 150. The anode 160 may be a sacrificial anode or an inert anode. The anode 160 may include an anode material 160a. In some exemplary aspects, the anode material 160a may be, but is not limited to, in the form of groups of spheres, particles, disks, cubes, sheets, or any other desired geometry (including amorphous).

[0081] In a non-limiting aspect, the anode material 160a may be disposed in the anode basket 165. The anode basket 165 may be formed of a conductive metal (e.g., titanium) that is insoluble in the electrolyte solution 148 and capable of maintaining a positive voltage potential and allowing metal ions to be released from the anode material 160a contained therein. In a non-limiting aspect, the anode basket 165 may include a body having a group of walls 164 arranged to define a basket interior 167 therebetween. For example, each wall 164 may have a first inward facing surface 164a facing the basket interior 167 and a opposing second outward facing surface 164b facing the exterior of the anode basket 165. The anode basket 165 may also include a base plate or bottom 166. The bottom 166 may define a group of first orifices 166a through which the group of first orifices 166a is arranged to allow an electrolyte flow 149 to flow from the exterior of the anode basket 165 into the basket interior 167 and through or across the anode material 160a. In some respects, the bottom 166 may also provide or define a support surface for the anode material 160a. The first orifice 166a may be smaller than the anode material 160a to prevent the anode material 160a from flowing into the first orifice 166a. In a non-limiting aspect, the size, shape, and relative orientation of the first orifice 166a may be selectively configured to affect any desired properties or characteristics of the electrolyte flow 149, including the velocity and direction of the electrolyte flow 149.

[0082] In a non-limiting aspect, the anode basket 165 may also include a top plate or cover 169. The cover 169 may define a group of second orifices 169a through which the group of second orifices 169a is arranged to allow an electrolyte flow 149 to flow through and out from the basket interior 167 to the exterior of the anode basket 165. In a non-limiting aspect, the size, shape, and relative orientation of the second orifices 169a may be selectively configured to influence any desired properties or characteristics of the electrolyte flow 149, including the velocity and direction of the electrolyte flow 149, without departing from the scope of this disclosure. In other aspects, the cover 169 may be omitted, such that the anode basket has an open top. In some aspects, one or more walls 164 may define a corresponding group of third orifices 164c through which the electrolyte solution 148 flows in or out, or both.

[0083] Method 300 may include, at 350, positioning the cathode 180 in a bath 145 downstream of the anode 160. In a non-limiting aspect, the cathode 180 may be a mandrel 182 having an external metal layer 183 (e.g., an external coating). For example, in a non-limiting aspect, the external metal layer 183 may be formed of copper, silver, or nickel, but is not limited thereto. In a non-limiting aspect, the external metal layer 183 may be applied to the mandrel 182 via sputtering, spraying, coating, or a similar process to facilitate the formation of the cathode 180.

[0084] Mandrel 182 may include mandrel body 185, which, as a non-limiting example, is formed of recyclable material. For example, mandrel body 185 may be formed of recyclable material that can be collected after the electroforming process and reused as another body in another electroforming process. Suitable recyclable materials may include wax, plastic, polymer foam, metal, or deformable materials, such as those that can be collected via melting or leaching in the non-limiting example. After the electroforming process is completed, mandrel body 185 can be recycled from the electroformed component, such as by heating and melting mandrel body 185 at elevated temperatures to recover structural material. Mandrel 182 may define or correspond to the shape of metal component 138.

[0085] Method 300 may include, at 355, electrically connecting an electrical power supply 190 to an anode 160 and a cathode 180 to provide a current 195 therebetween via an electrolytic solution 148. The electrical power supply 190 may be electrically connected to the anode 160 and the cathode 180 via an electrical conduit 191 to form a circuit 192 via the electrolytic solution 148. The electrical power supply 190 may operatively create an electric field 193 across the electrolytic solution 148 between the anode 160 and the cathode 180. The current 195 may cause metal ions to move from the anode 160 to the cathode 180 and deposit onto the mandrel 182.

[0086] In a non-limiting aspect, method 300 may optionally include, at 360, a cathode shield 170 disposed in a bath 145 between anode 160 and cathode 180. The cathode shield 170 may be formed of a non-conductive or ion-resistive material. In a non-limiting aspect, the cathode shield 170 may be formed of a dielectric material, including but not limited to polymers, glass, and ceramics. For example, the cathode shield 170 may be made of polyethylene, polypropylene, or a fluoropolymer (e.g., Teflon). ® It is made of materials such as PVDF.

[0087] In a non-limiting aspect, the cathode shroud 170 includes a cathode shroud body 171 defining a group of cathode shroud apertures 176 therethrough. The cathode shroud apertures 176 may be customized in size and orientation to receive an electrolyzer fluid flow 149 therethrough. The cathode shroud apertures 176 may be axially spaced apart from each other along the length of the cathode shroud 170. At least a subgroup of the group of cathode shroud apertures 176 may be aligned with the cathode 180 (e.g., relative to the direction of the electrolyzer fluid flow 149). The group of cathode shroud apertures 176 may be customized in size and arrangement to control, guide, or direct the velocity or direction of the electrolyzer fluid flow 149, or both.

[0088] Advantageously, the method 300 described herein allows for improved control over the thickness of electroformed metal components compared to conventional techniques. Furthermore, method 300 provides a method for producing metal components with reduced porosity compared to conventional methods. The reduced porosity provided by method 300 can enhance the aerodynamic performance of the metal component when used as a fan blade shroud 37. Additionally, system 110 and method 300, as disclosed herein, can reduce anode bridging without the need for mechanical agitators. In summary, this simplification of the manufacturing process reduces time, cost, and defects, and can provide comprehensive improvements to the final product compared to similar metal components formed by different methods, such as improved smoothness, reduced porosity, or controlled thickness, and combinations thereof. Furthermore, system 110 and method 300, as disclosed herein, enable improved thickness and distribution control compared to conventional systems and methods, for example, by providing controlled electron flow and controlled electrolytic solution fluid flow.

[0089] To a degree not yet described, different features and structures of each aspect can be used in combination as needed. The fact that a feature cannot be shown in all aspects is not to be interpreted as meaning it cannot be shown, but rather for the sake of brevity. Therefore, various features of different aspects can be mixed and matched as needed to form new examples, whether or not these new examples are explicitly described. The combinations or arrangements of features described herein are covered by this disclosure. In addition to those shown in the figure above, this disclosure contemplates many other possible aspects and constructions.

[0090] This written description uses examples to illustrate aspects of the disclosure described herein, including best practices, and also enables any person skilled in the art to implement aspects of the disclosure, including making and using any apparatus or system and performing any combined methods. The patentable scope of aspects of this disclosure is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not distinct from the literal language of the claims, or if they include equivalent structural elements that are not significantly different from the literal language of the claims.

[0091] Further aspects of this disclosure are provided by the subject matter of the following provisions: A system for electroforming metal components includes: a bath configured to contain an electrolyte solution, the bath having a fluid inlet pipe and a fluid outlet pipe fluidly connected to the electrolyte solution; a fluid pump connected in fluid communication to the fluid inlet pipe to supply the electrolyte solution thereto, and connected in fluid communication to the fluid outlet pipe to receive the electrolyte solution therefrom; an injection manifold connected in fluid communication to the fluid inlet pipe to receive the electrolyte solution therefrom, the injection manifold including a group of injection nozzles configured to inject the electrolyte solution therefrom into the bath to define an electrolyte solution fluid flow within the bath, the electrolyte solution fluid flow extending from the injection manifold to the fluid outlet pipe; an anode disposed in the bath downstream of the injection manifold relative to the electrolyte solution fluid flow; a cathode disposed in the bath downstream of the anode relative to the electrolyte solution fluid flow; and an electrical power supply electrically connected to the anode and cathode to provide current therebetween through the electrolyte solution in the bath.

[0092] In a system according to any of the foregoing provisions, the injection nozzles are axially spaced from each other along the length of the injection manifold.

[0093] In a system according to any of the foregoing provisions, the anode includes an anode basket configured to support anode material, the anode basket defining a group of first orifices therethrough, the group of first orifices being arranged to receive an electrolyte fluid flow therethrough and being in fluid communication with the anode material.

[0094] In a system according to any of the foregoing provisions, the anode basket is formed of a conductive material.

[0095] The system according to any of the foregoing provisions also includes a cathode shield comprising a cathode shield body formed of a dielectric material, the cathode shield being disposed in the bath between the anode and the cathode and in fluid communication with the electrolyte solution.

[0096] In a system according to any of the foregoing provisions, the cathode shroud includes a group of cathode shroud orifices defined therethrough, the cathode shroud orifices being configured to receive an electrolyte fluid flow therethrough.

[0097] In a system according to any of the foregoing provisions, the cathode includes a mandrel.

[0098] In any of the foregoing provisions, the mandrel is formed using recyclable materials.

[0099] In a system according to any of the foregoing provisions, the mandrel includes an outer metal layer.

[0100] In a system according to any of the foregoing provisions, the bath includes a heater configured to heat an electrolytic solution.

[0101] In a system according to any of the foregoing clauses, the metal component is a fan blade shroud for the fan blades.

[0102] A method for electroforming a metal component, the method comprising: disposing an electrolyte solution in a bath having a fluid inlet pipe and a fluid outlet pipe, the fluid inlet pipe and the fluid outlet pipe being fluidly connected to the electrolyte solution; immersing an injection manifold including a group of injection nozzles in the electrolyte solution in the bath; connecting the injection manifold to fluid communication with the fluid inlet pipe; connecting a fluid pump to fluid communication with the fluid outlet pipe to receive the electrolyte solution therefrom; connecting a fluid pump to fluid communication with the fluid inlet pipe to supply the electrolyte solution thereto; pumping the electrolyte solution from the fluid inlet pipe to the injection manifold; injecting the electrolyte solution from the injection manifold into the bath to define an electrolyte solution fluid flow within the bath, the electrolyte solution fluid flow extending from the injection manifold to the fluid outlet pipe; disposing an anode in the bath downstream of the injection manifold relative to the electrolyte solution fluid flow; disposing a cathode in the bath downstream of the anode relative to the electrolyte solution fluid flow; and electrically connecting a power supply to the anode and cathode to provide current therebetween via the electrolyte solution.

[0103] According to any of the foregoing provisions, the injection nozzles are axially spaced from each other along the length of the injection manifold.

[0104] According to any of the foregoing provisions, the anode includes an anode basket configured to support anode material, the anode basket defining a group of first orifices therethrough, the group of first orifices being arranged to receive an electrolyte fluid flow therethrough, and being in fluid communication with the anode material.

[0105] According to any of the foregoing provisions, the anode basket is formed of a conductive material.

[0106] The method according to any of the foregoing clauses further includes placing a cathode shield having a cathode shield body formed of dielectric material in a bath between the anode and the cathode, in fluid communication with the electrolyte solution fluid flow.

[0107] According to any of the foregoing provisions, the cathode shroud includes a group of cathode shroud orifices defined therethrough, the cathode shroud orifices being configured to receive an electrolyte fluid flow therethrough.

[0108] The method according to any of the foregoing clauses, wherein the cathode includes a mandrel formed using recyclable materials.

[0109] According to any of the foregoing provisions, the bath includes a heater configured to heat the electrolytic solution.

[0110] According to any of the foregoing provisions, the metal component is a shroud for the fan blades.

Claims

1. A system for electroformed metal components, comprising: A bath is configured to contain an electrolyte solution, the bath having a fluid inlet pipe and a fluid outlet pipe, the fluid inlet pipe and the fluid outlet pipe being fluidly connected to the electrolyte solution; A fluid pump is connected in fluid communication to the fluid inlet pipe to supply the electrolytic solution thereto, and is connected in fluid communication to the fluid outlet pipe to receive the electrolytic solution therefrom; An injection manifold is connected in fluid communication to the fluid inlet pipe to receive the electrolyte solution therefrom, the injection manifold including a group of injection nozzles configured to inject the electrolyte solution therefrom into the bath to define an electrolyte solution fluid flow within the bath, the electrolyte solution fluid flow extending from the injection manifold to the fluid outlet pipe; The anode is disposed in the bath downstream of the injection manifold relative to the flow of the electrolytic solution; The cathode is disposed in the bath downstream of the anode relative to the fluid flow of the electrolytic solution; as well as An electrical power supply is electrically connected to the anode and the cathode to provide current between them through the electrolytic solution in the bath.

2. The system according to claim 1, wherein, The injection nozzles are spaced apart from each other along the length of the injection manifold.

3. The system according to claim 1, wherein, The anode includes an anode basket configured to support anode material, the anode basket defining a group of first orifices therethrough, the group of first orifices being arranged to receive the electrolyte solution fluid flow therethrough and being in fluid communication with the anode material.

4. The system according to claim 3, wherein, The anode basket is formed of a conductive material.

5. The system according to claim 1 further includes a cathode shield, comprising a cathode shield body formed of a dielectric material, the cathode shield being disposed in the bath between the anode and the cathode and in fluid communication with the electrolytic solution.

6. The system according to claim 5, wherein, The cathode shroud includes a group of cathode shroud apertures defined therethrough, the cathode shroud apertures being configured to receive the electrolyte fluid flow therethrough.

7. The system according to claim 1, wherein, The cathode includes a mandrel.

8. The system according to claim 7, wherein, The mandrel is formed using recyclable materials.

9. The system according to claim 8, wherein, The mandrel includes an outer metal layer.

10. The system according to claim 1, wherein, The bath includes a heater configured to heat the electrolyte solution.

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