System and method for electroforming a metal component

Abstract

The present invention relates to systems and methods for electroforming metal components. In particular, a system for electroforming metal components includes an anode spaced apart from a cathode in an electrolytic solution. The system can include a gas injection manifold for injecting gas into the electrolytic solution within the bath to define a gas flow. The system can also include an electrolytic solution injection manifold for injecting electrolytic solution into the bath through a set of fluid injection nozzles to define an electrolytic solution fluid flow. A cathode shroud can be disposed between the anode and the cathode.

Description

Technical Field

[0001] This disclosure generally relates to metal components, and more specifically, to a system for electroformed metal components. Background Technology

[0002] A turbine engine is a rotary engine that extracts energy from a flow of working air. The working air passes sequentially through a compressor section, a combustor section, and a turbine section. The compressor section compresses the working air. The combustor section adds fuel to the compressed air and ignites it. The turbine section expands and extracts work from the working air to drive the compressor section along with other systems, providing thrust. The compressor and turbine stages consist of pairs of rotating blades and fixed guide vanes arranged axially. The groups of rotating blades are arranged circumferentially around the engine's centerline.

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

[0004] Technical Solution 1. A system for electroformed metal components, comprising: A bath configured to contain an electrolyte solution, the bath having a gas inlet pipe in fluid connection with the electrolyte solution; The anode is disposed in the bath; A cathode, which is disposed in the bath spaced apart from the anode; An electrical power supply, electrically connected to the anode and the cathode, provides current from the anode to the cathode through the electrolytic solution in the bath; A gas source, connected in fluid communication with the gas inlet pipe to supply gas thereto; and A gas injection manifold, disposed in the bath and connected in fluid communication with the gas inlet pipe to receive the gas therefrom, the gas injection manifold including a group of gas injection nozzles configured to inject the gas therefrom into the electrolyte solution within the bath to define a gas flow extending from the gas injection manifold to the cathode.

[0005] Technical Solution 2. The system according to Technical Solution 1, wherein the gas injection nozzles are spaced apart from each other along the length of the gas injection manifold in the axial direction.

[0006] Technical Solution 3. The system according to Technical Solution 1, wherein the anode includes an anode basket configured to support the anode material.

[0007] Technical Solution 4. The system according to Technical Solution 3, wherein the anode basket is formed of a conductive material.

[0008] Technical Solution 5. The system according to Technical Solution 3, wherein the gas injection manifold is connected to the anode basket.

[0009] Technical Solution 6. The system according to Technical Solution 5, wherein the anode basket defines a slot, and wherein the gas injection manifold is disposed within the slot.

[0010] Technical Solution 7. The system according to Technical Solution 1, wherein the gas injection manifold is disposed between the anode and the cathode.

[0011] Technical Solution 8. The system according to Technical Solution 1 further includes a cathode shield disposed between the anode and the cathode.

[0012] Technical Solution 9. The system according to Technical Solution 1, wherein the metal component is a fan blade cover for the fan blades.

[0013] Technical Solution 10. The system according to Technical Solution 1, wherein the bath further includes a fluid inlet pipe and a fluid outlet pipe, both of which are fluidly connected to the electrolytic solution, and the system further includes: A fluid pump, connected in fluid communication with the fluid outlet pipe to receive the electrolytic solution therefrom, and further connected in fluid communication with the fluid inlet pipe to supply the electrolytic solution thereto; and An electrolyte injection manifold, fluidly connected to the fluid inlet pipe to receive the electrolyte solution therefrom, the electrolyte injection manifold including a group of fluid 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 flowing toward the anode and downstream toward the cathode.

[0014] Technical Solution 11. The system according to Technical Solution 10, wherein the anode includes an anode basket configured to support the anode material, and The anode basket is defined by a group of first orifices therethrough, the first orifices being arranged to receive the electrolyte solution fluid flow in fluid communication with the anode material.

[0015] Technical Solution 12. A method for electroforming metal components, the method comprising: The electrolyte solution is placed in a bath with a gas inlet pipe; A gas injection manifold, comprising a group of gas injection nozzles, is immersed in the electrolytic solution in the bath, and is in fluid communication with the gas inlet pipe to receive gas therefrom; The gas is injected from the gas injection manifold into the bath to define a gas flow within the bath; The anode is placed in the bath; The cathode is disposed in the bath spaced apart from the anode; and A power supply is electrically connected to the anode and the cathode to provide current between them through the electrolyte solution.

[0016] Technical Solution 13. The method according to Technical Solution 12, wherein the gas injection nozzles are spaced apart from each other along the length of the gas injection manifold in the axial direction.

[0017] Technical Solution 14. The method according to Technical Solution 12, wherein the gas injection manifold is disposed between the anode and the cathode.

[0018] Technical Solution 15. The method according to Technical Solution 12, wherein the anode includes an anode basket configured to support the anode material.

[0019] Technical Solution 16. The method according to Technical Solution 15, wherein the anode basket is formed of a conductive material.

[0020] Technical Solution 17. The method according to Technical Solution 15, wherein the gas injection manifold is connected to the anode basket.

[0021] Technical Solution 18. The method according to Technical Solution 17, wherein the anode basket defines a slot, and wherein the gas injection manifold is disposed within the slot.

[0022] Technical Solution 19. The method according to Technical Solution 14 further includes: An electrolytic solution injection manifold comprising a group of fluid injection nozzles is immersed in the electrolytic solution in the bath; and The electrolyte solution is injected from the electrolyte solution injection manifold into the bath to define an electrolyte solution fluid flow within the bath, the electrolyte solution fluid flow being directed toward the anode and downstream toward the cathode.

[0023] Technical Solution 20. The method according to Technical Solution 19, wherein the anode includes an anode basket configured to support an anode material, the anode basket defining a group of first orifices therethrough, which are arranged to receive the electrolyte solution fluid flow in fluid communication with the anode material. Attached Figure Description

[0024] In the diagram: Figure 1 This is a schematic diagram of a turbine engine based on an exemplary aspect of this disclosure.

[0025] Figure 2A This is a schematic diagram of a system for forming metal components according to an exemplary aspect of this disclosure.

[0026] Figure 2B It is along Figure 2A The cross section taken from line II-II.

[0027] Figure 3 This is a schematic diagram of a system for forming metal components according to another exemplary aspect of this disclosure.

[0028] Figure 4 This is a schematic diagram of a system for forming metal components according to yet another exemplary aspect of this disclosure.

[0029] Figure 5 This is a schematic diagram of a system for forming metal components according to another exemplary aspect of this disclosure.

[0030] Figure 6 This is a flowchart illustrating a method for electroforming metal components according to an exemplary aspect of this disclosure. Detailed Implementation

[0031] 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, compared with conventional methods and systems, provide improved wall thickness control, reduced porosity and pitting corrosion of the metal components, and reduced transanodic and cathodic interactions.

[0032] 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, as discussed herein, is not limited thereto, but is generally applicable to electroforming any desired metal components for any desired application, including non-aerospace applications, such as other mobile applications, and non-mobile industrial, commercial, and residential applications, without departing from the scope of this disclosure.

[0033] Reference will now be made to the various aspects, with one or more examples shown in the accompanying drawings. Numerical and alphabetic designations are used in the detailed description to refer to the features in the accompanying drawings.

[0034] The term “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as equivalent to other implementations being preferred or advantageous. Furthermore, unless expressly identified otherwise, all aspects described herein should be considered exemplary.

[0035] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of a single component unless otherwise specified.

[0036] The singular forms “a,” “an,” and “the” include plural references unless the context clearly specifies otherwise. Furthermore, as used herein, the term “group” or “group of” elements can refer to any number of elements, including a single element.

[0037] 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.

[0038] As used herein, 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 within the electrolyte, the anode material, the cathode material, and the properties of the electrolyte, such as ion concentration, conductivity, resistivity, temperature, viscosity, pH, chemical stability, additives, and impurities.

[0039] As used herein, the term “monolithic monolithic body” or “monolithic body” refers to a single body that is a single, indivisible object, or is formed as a single, single object during manufacturing, as opposed to being formed by combining individual elements into one during manufacturing.

[0040] As used herein, 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.

[0041] The terms "front" or "front part" refer to what is in front of something, while "rear" or "rear part" 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.

[0042] Furthermore, as used herein, the term "radial" or "along the radial direction" refers to a dimension away from a common center. For example, in the overall context of a turbine engine, radial refers to the direction along a ray extending between the engine's central longitudinal axis and the engine's outer perimeter.

[0043] 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 use of aspects of this disclosure described herein.

[0044] Connections (e.g., attachments, joins, connections, and linkages) should be interpreted broadly and, unless otherwise identified, may include intermediate structural elements between a set of elements and relative movement between elements. Therefore, a connection does not necessarily mean that two elements are directly connected and in a fixed relationship with each other. The exemplary drawings are for illustrative purposes only, and the dimensions, positions, orders, and relative sizes reflected in the attached drawings are subject to change.

[0045] Conventional gas turbine engines may include fan sections with airfoils. For example, these airfoils 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.

[0046] During the operation of a gas turbine engine (such as during flight), foreign objects may become trapped in the engine inlet and impact the fan blades, causing damage. For example, foreign objects may include birds, rainwater, hail, ice, or other debris. Impacts from relatively large objects (such as birds) may tear the blades, causing blade fragments to fly radially outward at high speed. Furthermore, impacts from relatively small foreign objects (such as sand) can gradually erode the blade material, leading to a decrease in fan and engine performance.

[0047] One known solution to reduce damage to fan blades from impacts caused 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, especially the leading edge. Fan blade shrouds also allow impact energy to be transferred over an area larger than the point of impact.

[0048] Traditional 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, 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 an impact from airborne debris.

[0049] Titanium and its 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 the production of fan blade shrouds through electroforming.

[0050] In a conventional electroforming process, a cathode (e.g., a negatively charged electrode) in the form of a mandrel or the article to be electroplated as a substrate is immersed in a suitable electrolyte solution, and an electric current (e.g., the plating current) flows through the electrolyte solution 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 flowing through the electrolyte solution causes the article to be electroformed onto the cathode with a desired metal or alloy surface layer. The anode and cathode are placed in the electrolyte solution and electrically connected to a power supply (sometimes called a power source), which generates an electric field in the electrolyte solution between the anode and cathode and supplies a direct current (DC) current to the anode. This current oxidizes the metal, allowing the metal atoms of the anode to dissolve as metal cations in the electrolyte solution. The current then causes 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.

[0051] Typically, the anode has a similar approximate composition to 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 consumed due to electroplating or molding on the article. The anode material typically serves a dual function: simultaneously completing the circuit between the anode and cathode and replenishing the metal content of the electrolyte solution.

[0052] Typically, a composite structure (often called a "basket") that is conductive but chemically inert with respect to the electrolyte solution is used to support or contain the anode material. The anode material can be formed into relatively small objects (sometimes called flakes, coins, pellets, or ingots, etc.), and these sheet-like materials are arranged in electrical contact with each other and with the conductive anode basket. The anode basket is typically suspended in the electrolyte solution from a conductive support rod or other support structure. The electrolyte solution is in fluid communication with the anode material contained therein through an opening provided in the anode basket. During operation, the anode material can be gradually consumed and replaced as needed at appropriate time intervals.

[0053] 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 formed of a conductive material, such as titanium. The outer surface of the mandrel may conform (sometimes referred to as conforming) 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 achieved by a well-known “shrouding” process, in which a non-conductive barrier wall or “cathode shield” is placed near the mandrel to influence or guide the current flowing through the electrolyte solution between the anode and cathode. After the mandrel has been left in the electrolyte solution under the influence of an electric field for a predetermined time, it is removed. The electrodeposited material on the outer surface of the mandrel is mechanically removed from the mandrel as the newly electroformed fan blade shroud. The fan blade shroud can then be machined in a manner well known in the art to allow it to fit smoothly onto the corresponding fan blade.

[0054] However, conventional fan blade shrouds for gas turbine engines are typically limited by a thickness range 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), which is roughly 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 tight tolerances and coating uniformity, and therefore pose challenges to electroformed fan blade shrouds.

[0055] One problem associated with conventional techniques for electroforming metal components is that, since the material deposition rate is proportional to the current density, any inhomogeneity in the current density distribution between the anode and cathode can require more time to achieve the desired thickness of deposited material, resulting in a time-consuming and costly process. The portion of the cathode closer to the anode (e.g., raised areas) is exposed to a higher current density, and therefore more metal is deposited on the raised areas of the cathode compared to the portion further away from the anode (e.g., recessed areas). The faster deposition in the raised areas thus increases the current density, and consequently the deposition rate in the raised areas, and similarly decreases the deposition rate in the recessed areas. This inhomogeneous distribution of current density not only leads to inhomogeneous distribution of deposited material but can also result in dendrite or similar crystal formation on the cathode. Typically, to reduce crystal formation, conventional electroforming processes are performed at minimum current densities, thus requiring a significant amount of time to achieve the desired thickness of the electroformed metal layer. However, even at low current densities, inhomogeneous material deposition can still occur. In some cases, the electroforming process can be interrupted and the object removed from the electrolyte to perform additional steps such as cutting or removing dendrites and portions of the metal deposited in protruding areas, thereby reducing the increased current density in these areas. Electroforming at higher current densities accelerates the deposition rate but worsens inhomogeneity and increases the rate of dendrite accumulation.

[0056] Another problem in conventional electroforming operations is that as individual anode material objects gradually decrease in size over time, voids are created in the anode material due to bridging of these individual anode objects. 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 anode basket. Bridging also results in the amount of anode material in contact with the electrolyte varying over time, leading to poor uniformity of the deposited material and increased porosity on the electroformed surface.

[0057] One known solution to overcome anode bridging is to shake the anode basket to cause the anode material to settle to the bottom, allowing for proper refilling of the basket. Typically, shaking the anode basket to cause the anode material to settle is done either manually (e.g., by rocking the basket) or by using a mechanical or motor-driven mechanism to shake or vibrate the basket to induce settlement. Such techniques and / or mechanisms can add additional costs and, in some cases, can damage the basket.

[0058] Another problem associated with conventional electroforming technology is that bubbles (such as hydrogen gas) inevitably form on the surface of the cathode during electroforming. Such bubbles can lead to undesirable pitting or porosity on the surface of the electroformed component.

[0059] To better address the challenges of the gas turbine industry's need for tight tolerances in electroformed metal components to produce reliable and high-performance gas turbines, it is desirable to provide an improved system for electroformed fan blade shrouds that offers enhanced operating efficiency and a reasonable cost.

[0060] For example, as disclosed herein, a gas injection manifold can be provided to operatively inject a gas stream into the electrolyte during electroforming operations, the gas stream being able to agitate, expel, or otherwise remove bubbles formed on the cathode surface. Furthermore, when arranged upstream of the anode, the gas injection manifold can additionally inject a gas stream into the electrolyte during electroforming operations to agitate the anode basket, causing the anode material to settle, thereby reducing bridging of the anode material without the need for a mechanical agitator.

[0061] As disclosed herein, an electroforming system may additionally be provided, comprising a fluid pump and an injection manifold including a group of nozzles arranged to cooperatively inject an electrolytic fluid flow from the anode to the cathode. The electrolytic fluid flow enables controlled ion flow through the electrolyte solution, allowing for improved control over the thickness of the electroformed metal component compared to conventional techniques. Furthermore, the electrolytic fluid flow can agitate, expel, or otherwise remove bubbles (e.g., hydrogen gas) that may form on the cathode surface during the electroforming operation.

[0062] Compared to conventional methods, the systems and methods disclosed herein allow for the production of metal components with reduced porosity and pitting. The reduced porosity and pitting provided by the aspects disclosed herein can enhance the aerodynamic performance of metal components when used as fan blade shrouds.

[0063] As disclosed in this article, a non-limiting aspect may also be provided, which is a conforming anode having a shape that conforms to the shape of the cathode to provide a uniform distribution of current density and thus a uniform distribution of deposited material.

[0064] Additionally, the aspects disclosed herein may include a cathode shield placed between the anode and cathode to influence or guide the current flowing through the electrolyte from the anode and cathode, to further arrange a uniform ion flow through the electrolyte, thereby resulting in uniform deposition of the anode material on the cathode.

[0065] Figure 1This 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.

[0066] 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 outward from fan disk 41 generally in a radial direction. Fan blades 42 can be at least partially formed of a composite material (such as carbon fiber). Additionally, or alternatively, fan blades 42 can be at least partially formed of a metal alloy.

[0067] 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. It should be noted that the fan blade shroud 37 is curved and twisted 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.

[0068] The fan blade shroud 37 provides protection against damage such as impact and corrosion. The fan blade shroud 37 may be formed, at least partially, using additive manufacturing techniques, employing any suitable metallic alloy or non-metallic material, such as those described herein. In a non-limiting aspect, the fan blade shroud 37 may have a monolithic structure.

[0069] 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 produces combustion gases. The engine core 44 is surrounded by a core housing 46, which is connectable to the fan housing 40.

[0070] An HP shaft or rod 48, coaxially arranged around the engine centerline 12 of the gas turbine engine 10, drives the HP turbine 34 to the HP compressor 26. An LP shaft or rod 50, coaxially arranged within a larger diameter annular HP shaft 48 around the engine centerline 12 of the gas turbine engine 10, drives the LP turbine 36 to the LP compressor 24 and the fan 20. Shafts 48 and 50 are rotatable around the engine centerline 12 and are connected to multiple rotatable elements that together constitute a rotor 51.

[0071] LP compressor 24 and HP compressor 26 each include multiple compressor stages 52 and 54, in which groups of compressor blades 56 and 58 rotate relative to corresponding groups of static compressor guide vanes 60 and 62 (also called 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 can be arranged in a ring and can extend radially outward relative to the engine centerline 12, from the blade platform to the blade tip, while the corresponding compressor guide vanes 60 and 62 are positioned upstream of and adjacent to the rotating blades 56 and 58. It is important to note that the selection... Figure 1 The numbers of blades, guide vanes, and compressor stages shown are for illustrative purposes only, and other numbers are possible.

[0072] Blades 56, 58 for the compressor stages may be mounted on a compressor disk 61, which is mounted on a corresponding one of the HP and LP shafts 48, 50, wherein each stage has its own compressor disk 61. Blades 56, 58 may be part of the disk, rather than mounted on the disk. Guide vanes 60, 62 for the compressor stages may be circumferentially arranged and mounted on the core housing 46.

[0073] HP turbine 34 and LP turbine 36 each include multiple turbine stages 64 and 66, in which groups of turbine blades 68 and 70 rotate relative to corresponding nozzles 73 and 75. The nozzles 73 and 75 include corresponding groups of static turbine guide vanes 72 and 74 to extract energy from the fluid flow passing 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 extend radially outward relative to the engine centerline 12, from the blade platform to the blade tip, while the corresponding turbine guide 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 guide vanes 72 and 74 may be airfoil-shaped. It should be noted that the selection... Figure 1 The numbers of blades, guide vanes, and turbine stages shown are for illustrative purposes only, and other numbers are possible.

[0074] Blades 68, 70 for the turbine stages can be mounted on a turbine disk 71, which can be mounted on a corresponding one of the HP and LP shafts 48, 50, with each stage having a dedicated turbine disk 71. Guide vanes 72, 74 for the compressor stages can be circumferentially arranged and mounted on the core housing 46.

[0075] Complementing the rotor section, the stationary sections of the gas turbine engine 10, such as the guide 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 all non-rotating elements throughout the gas turbine engine 10.

[0076] In operation, the airflow leaving fan section 18 is split, such that a portion of the airflow is directed to 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, producing combustion gases. Some work is extracted from these gases by HP turbine 34, which drives HP compressor 26. The combustion gases are discharged to LP turbine 36, which extracts additional work to drive LP compressor 24, and the exhaust gases are finally 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.

[0077] 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 fixed guide vane array, and more specifically through the outlet guide vane assembly 80 (comprising multiple airfoil guide vanes 82) at the fan exhaust port 84. More specifically, radially extending airfoil guide vanes 82 arranged in a circumferential array are used near the fan section 18 to exert some directional control on the bypass airflow 78.

[0078] 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 high-temperature sections, and / or to cool other aspects of the aircraft or power them. In the context of a turbine engine, the high-temperature sections of the engine are typically located downstream of combustor 30, particularly turbine section 32, which is located directly downstream of combustion section 28. Other sources of cooling fluid may include, but are not limited to, fluid discharged from LP compressor 24 or HP compressor 26.

[0079] Figure 2AA schematic diagram of a non-limiting aspect of a system 110 for an electroformed metal component 138, as disclosed herein, is depicted. The system 110 may include an electrodeposition bath 140 having a bath tank 145 containing an electrolyte solution 148. The electrolyte solution 148 is conductive. The bath tank 145 may include a fluid inlet conduit 141 and a fluid outlet conduit 143. The system 110 may also include an electrolyte solution injection manifold 150 defining a group of openings or fluid injection nozzles 159. An anode 160, a cathode 180, and the electrolyte solution injection manifold 150 may be immersed in or disposed in the electrolyte solution 148. The anode 160 is spaced apart from the cathode 180. The anode 160 is disposed between the electrolyte solution injection manifold 150 and the cathode 180. Any number of mechanical supports or hangers 145a may be used to position the electrolyte solution injection manifold 150, the anode 160, and the cathode 180 in the bath tank 145 as desired. System 110 may also include a fluid pump 147. A power supply 190 (e.g., a DC power supply) may be located outside the bath 145 and electrically connected to the anode 160 and the cathode 180.

[0080] Bath 145 contains an electrolyte solution 148. In a non-limiting aspect, the electrolyte solution 148 may comprise an aluminum alloy carrying alloy metal ions. In another non-limiting example, the electrolyte solution 148 may comprise a nickel alloy containing 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).

[0081] Fluid pump 147 is connected in fluid communication with fluid inlet pipe 141 and fluid outlet pipe 143 to provide 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 electrolyte solution injection manifold 150 to supply electrolyte solution 148 thereto. Fluid outlet pipe 143 is arranged in fluid communication with the electrolyte solution 148 disposed in bath 145 to receive the electrolytic fluid flow 149 therefrom.

[0082] In a non-limiting aspect, fluid inlet conduit 141 is arranged at a first end (e.g., bottom) of bath 145, while fluid outlet conduit 143 is located 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 143 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 143 may be arranged or oriented in various ways about each other as desired, so that electrolytic fluid flow 149 can flow from upstream to downstream, from fluid inlet conduit 141 to electrolyte injection manifold 150, to anode 160, to cathode 180, and to fluid outlet conduit 143.

[0083] Fluid pump 147 allows the electrolyte solution 148 to be circulated or recirculated through bath 145 via fluid inlet pipe 141 and fluid outlet pipe 143. In some non-limiting aspects, filter 144 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, filter 144 may include a chemical filter medium. Optionally, heater 146 may be provided to regulate the temperature of the electrolyte solution 148 in bath 145. In a non-limiting example, heater 146 may be located inside bath 145 or near bath 145 outside bath 145. Alternatively, heater 146 may be in fluid communication with fluid pump 147 to heat electrolyte solution 148 as it is pumped by fluid pump 147.

[0084] A 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 power supply 190 is operatively capable of generating 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 power supply 190 and the anode 160 and cathode 180. The power supply 190 may be configured to provide a current 195 (shown as a 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 (not shown) to move from the anode 160 to the cathode 180 and deposit thereon.

[0085] The surface geometry of the cathode 180 may be based on or conform to the desired geometry of the metal component 138 to be electroformed. In a non-limiting aspect, the cathode 180 may include a mandrel 182 having a mandrel body 185. The mandrel body 185 may have an outer mandrel surface 185a. The mandrel surface 185a is shaped and arranged to conform to the desired shape of the metal component 138 to be electroformed. The outer mandrel surface 185a may be formed of a conductive material (e.g., a coating). For example, in a non-limiting aspect, the conductive material may be copper, silver, or nickel, without limitation. It is contemplated that the conductive material may be applied to the mandrel body 185 via spraying, smearing, coating, or similar treatment to facilitate the formation of the cathode 180.

[0086] As a non-limiting example, the mandrel body 185 may be formed from recyclable materials. For example, the mandrel body 185 may be made from recyclable materials that can be collected after the electroforming process and reused as another body in another electroforming process. Suitable recyclable materials may include waxes, plastics, polymer foams, metals, or deformable materials, such as those that can be collected via melting or extraction, in non-limiting examples. After the electroforming process is completed, the mandrel body 185 may be recycled from the electroformed component, such as by heating and melting the mandrel body 185 at elevated temperatures to recover structural materials.

[0087] In a non-limiting aspect, anode 160 may be a matched anode. For example, anode 160 may have a surface geometry that matches or complements the surface geometry of cathode 180 (e.g., outer mandrel surface 185a) or the surface geometry of the metal member 138 to be formed. In other aspects, anode 160 may be a non-matched anode.

[0088] Figure 2B Depicting along Figure 2A The image shows a cross-section of system 110 taken by line II-II, where some components are omitted for clarity. As shown, the electrolyte injection manifold 150 includes at least one wall 150a arranged to define a manifold interior 158. This at least one wall 150a may also define a group of fluid injection nozzles 159 therethrough. Therefore, the manifold interior 158 defines a passage for an electrolyte fluid flow 149, which is in fluid communication with the group of fluid injection nozzles 159. The electrolyte injection manifold 150 is coupled to a first fluid inlet conduit 141 (…). Figure 2A The fluid is connected to receive the electrolytic fluid flow 149. Thus, the electrolytic fluid flow 149 can be arranged from upstream to downstream, from the fluid inlet pipe 141 to the electrolyte injection manifold 150, and then radially outward through a group of fluid injection nozzles 159 into the bath 145, flowing toward the anode 160.

[0089] The anode 160 can be a sacrificial anode or an inert anode. Although one anode 160 is shown, it should be understood that the bath 145 can include any number of anodes 160 as desired. In some aspects, the anode material 160a can be in the form of groups of spheres, pellets, disks, cubes, sheets, or any other desired geometry (including amorphous). In a non-limiting aspect, the anode 160 can include a container or anode basket 165 arranged to hold or support the anode material 160a. The anode material 160a can be disposed in or on the anode basket 165. In such aspects, the anode basket 165 can have a surface geometry that matches or complements the cathode 180 or the metal member 138 to be formed.

[0090] The anode basket 165 may be formed of a conductive metal (e.g., titanium) that is insoluble in the electrolyte solution 148, 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 group of walls 164 arranged to define a basket interior 167 therebetween. For example, each wall 164 may have a first inward surface 164a facing the basket interior 167 and an opposing second outward surface 164b facing the exterior of the anode basket 165.

[0091] The anode basket 165 also includes a base plate or bottom 166. The bottom 166 may define a group of first orifices 166a therethrough, the group of first orifices 166a being arranged to allow an electrolytic fluid flow 149 to enter from the outside 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 166b for the anode material 160a. In a non-limiting aspect, the support surface 166b may have a surface geometry that matches or conforms to the surface geometry of the cathode 180 or the metal member 138 to be formed. The first orifices 166a may be smaller than the anode material 160a to prevent the anode material 160a from entering the first orifices 166a. Although the first orifices 166a are in... Figure 2B The examples shown are generally cylindrical and have substantially the same dimensions and orientations as each other, but other aspects are not limited thereto. It is contemplated that, in other aspects, the size, shape, and relative orientation of the first orifice 166a may be selectively constructed to achieve any desired characteristics or features of the electrolyzer flow 149, including, for example, the rate and direction of the electrolyzer flow 149, without departing from the scope of this disclosure.

[0092] The anode basket 165 may also include a top or cover 169. The cover 169 may have a first upstream surface 169a facing the basket interior 167 and an opposing second downstream surface 169b facing the cathode 180. In a non-limiting aspect, the second downstream surface 169b may have a surface geometry that matches or complements the cathode 180 or the metal member 138 to be formed.

[0093] The cover 169 may define a group of second openings 169c therethrough, the group of second openings 169c being arranged to allow the electrolytic fluid flow 149 to exit from the interior of the anode basket 167 to the exterior of the anode basket 165 through it. Although the second openings 169c are in Figure 2B The examples shown are generally cylindrical and have substantially the same dimensions and orientation as each other, but other aspects are not limited to this. It is contemplated that, in other aspects, the size, shape, and relative orientation of the second opening 169c can be selectively constructed to achieve any desired characteristics or features of the electrolytic fluid flow 149, including, for example, the rate and direction of the electrolytic fluid flow 149, without departing from the scope of this disclosure. It is also contemplated that, in other aspects, the cover 169 can be omitted, such that the anode basket 165 has an open top. In some aspects, one or more walls 164 can define corresponding groups of third orifices 164c therethrough to allow the electrolyte solution 148 to enter or exit, or both.

[0094] During operation, and simultaneously refer to Figure 2A and 2B The bath 145 can contain a suitable amount or level of electrolyte solution 148, sufficient to cover or submerge the electrolyte solution injection manifold 150, anode basket 165, and cathode 180. A fluid pump 147 is operable to circulate the electrolyte solution 148 through the bath 145 from fluid inlet pipe 141 to fluid outlet pipe 143. The electrolyte solution 148 flows into the electrolyte solution injection manifold 150, which injects the electrolyte solution 148 from a group of fluid injection nozzles 159 toward the anode 160, defining an electrolyte fluid flow 149. The electrolyte fluid flow 149 flows through a first orifice 166a and flows in fluid communication with the anode material 160a contained within the anode basket 165, flowing through gaps or spaces defined between and around the anode material 160a. In a non-limiting aspect, the electrolyte fluid flow 149 can then flow from the anode 160 to the cathode shroud 170.

[0095] Power supply 190 operably generates an electric field 193 between anode 160 and cathode 180, producing an electric field 193 across electrolyte solution 148, and can supply current 195 to anode 160 and from anode 160 through electrolyte solution 148 to cathode 180. Current 195 causes metal ions from anode material 160a (e.g., tungsten) to move from anode 160 to cathode 180 and deposit onto mandrel 182 to form metal member 138. In a non-limiting example, metal member 138 may be fan blade shroud 37. Figure 1 ).

[0096] The electrodeposition rate of the anode material 160a at any particular region of the cathode 180 will depend in part on a variety of factors, including the characteristics of the electric field 193 and the current 195 passing through the electrolyte solution 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 thickness profile (sometimes referred to as thickness distribution) of the metal ions electrodeposited on the mandrel 182 can be selectively controlled, at least in part, by adjusting the electric field 193 or guiding the electrolyte flow 149, or both, by configuring the size, shape, orientation, and combinations thereof of the anode 160. By configuring the anode 160 as a mating anode 160, a uniform electric field intensity can be arranged across the surface of the cathode 180, and stagnant regions or non-uniform flow of the electrolyte flow 149 can be reduced. This arrangement can provide a more uniform distribution of current density, and the anode material 160a can be deposited more uniformly onto the mandrel 182 than with conventional techniques.

[0097] Additionally, or alternatively, in a non-limiting aspect, the characteristics of the electrolytic fluid flow 149 can be further controlled by adjusting the rate, direction, or both of the electrolytic fluid flow 149. For example, in a non-limiting aspect, the fluid pump 147 can be configured to increase or decrease the rate of the electrolytic fluid flow 149 through the bath 145. In some non-limiting aspects, the rate or direction of the electrolytic fluid flow 149 through the bath 145 can be further controlled by configuring a group of fluid injection nozzles 159 as desired. In this way, the configuration of the anode 160, the electrolyte injection manifold 150, or the group of fluid injection nozzles 159 and their combinations can be coordinated to achieve the desired final thickness profile (e.g., flattened) of the metal member 138, thereby compensating for any non-uniform thickness profile that might otherwise be observed without the electrolyte injection manifold 150 in place.

[0098] Figure 3 A block diagram depicts another non-limiting aspect of a system 210 for performing an electroforming process to form a metal component 138, as disclosed herein. Figure 3 System 210 and Figure 2A-2B The system 110 depicted is similar to that described in the figure, therefore the same parts are marked with the same reference numerals. Figure 3 System 210 and Figure 2A-2B A significant difference between system 110 and system 210 is that system 210 also includes a gas inlet conduit 142 and a gas injection manifold 130 defining a group of openings or gas injection nozzles 132. The gas injection manifold 130 may be immersed in or positioned in the electrolyte solution 148 upstream of the cathode 180 (e.g., with respect to the electrolytic fluid flow 149). As shown, in a non-limiting aspect, the anode 160 may be positioned between the gas injection manifold 130 and the cathode 180. In other non-limiting aspects, the gas injection manifold 130 may be positioned between the anode 160 and the cathode 180. Any number of mechanical supports or hangers 145a may be used to position the gas injection manifold 130. System 210 may include a gas source 137, such as an air pump or pressurized gas tank, fluidly coupled to the gas injection manifold 130 to supply it with gas 135 (e.g., oxygen).

[0099] Gas source 137 may be connected in fluid communication with gas inlet conduit 142 to deliver a gas flow of gas 135 (indicated by a series of dashed arrows "139") into the electrolytic solution 148 within bath 145. Gas inlet conduit 142 may be connected in fluid communication with gas injection manifold 130 to supply gas flow 139 thereto.

[0100] The gas injection manifold 130 may include at least one wall 130a arranged to define a manifold interior 136. The at least one wall 130a may further define a group of gas injection nozzles 132 therethrough. Thus, the manifold interior 136 defines a passage for a gas flow 139 in fluid communication with the group of gas injection nozzles 132. The gas injection manifold 130 is coupled in fluid communication with a gas inlet conduit 142 to receive the gas flow 139. In this way, the gas flow 139 can be arranged to flow from the gas injection manifold 130 to the cathode 180. For example, the gas flow 139 may flow from upstream to downstream, from the gas inlet conduit 142 to the gas injection manifold 130, and then radially outward through the group of gas injection nozzles 132 into the bath 145, flowing towards the cathode 180.

[0101] During operation, Figure 3 System 210 and Figure 2A-2BSystem 110 operates similarly. However, system 210 may additionally provide a gas flow 139 from gas injection manifold 130 through the electrolyte solution 148 in electrolytic bath 145 during electroforming operations. The gas flow 139 may flow toward and through anode basket 165 or anode material 160a, or both. In this respect, the gas flow 139 may operatively agitate the anode material 160a. Agitation of the anode material 160a by the gas flow 139 may reduce anode bridging without the need for a mechanical agitator (e.g., shaking or swaying the anode basket 165). Additionally, the gas flow 139 may flow toward and impinge on cathode 180, and may further agitate or expel bubbles that may have formed on mandrel surface 185a. Agitation of any bubbles formed on mandrel surface 185a by the gas flow 139 may reduce pitting on metal components 138 without the need for a mechanical agitator (e.g., shaking or swaying the cathode 180).

[0102] Although the exemplary gas injection manifold 130 is in Figure 3 The gas injection manifold 130 is shown as being positioned upstream of the anode material 160a and supported by a hanger 145a, but is not otherwise limited thereto, and the gas injection manifold 130 may be supported and arranged in any number of other ways without departing from the scope of this disclosure.

[0103] For example, Figure 4 A portion of another exemplary system 310 for performing an electroforming process to form a metal component 138 is depicted, showing only the anode 160 and the gas injection manifold 130, with other components omitted for clarity. Figure 4 System 310 and Figure 2A-2B and Figure 3 The systems 110 and 210 depicted are similar, therefore the same parts are marked with the same reference number. Figure 4 System 310 and Figure 2A-2B and Figure 3 A significant difference between systems 110 and 210 is that system 310 also depicts an exemplary aspect in which the gas injection manifold 130 is supported by an anode basket 165 and is located between the anode material 160a and the cathode 180. Figure 4 System 310 and Figure 4 System 310 and Figure 3 Another difference between System 210 and System 210 is that... Figure 4 System 310 does not include the electrolyte injection manifold 150.

[0104] In the illustrated exemplary embodiment, cover 169 may define a recess or notch 269 therein. Gas injection manifold 130 may be disposed within notch 269 and may be supported by anode basket 165. Brackets or straps (not shown) may be used to hold gas injection manifold 130 within notch 269. In other respects, gas injection manifold 130 may be supported by any other portion of anode basket 165 as desired, without departing from the scope of this disclosure.

[0105] By positioning the gas injection manifold 130 close to the cathode 180 (e.g., between the anode 160 and the cathode 180), the gas flow 139 can more easily agitate or expel bubbles that may have formed on the cathode 180 or the metal component 138 than when the gas injection manifold 130 is positioned between the anode material 160a and the cathode 180.

[0106] Figure 5 A block diagram depicts another non-limiting aspect of a system 410 for performing an electroforming process to form a metal component 138, as disclosed herein. Figure 5 System 410 and Figure 2A-2B and Figure 3-4 The systems 110, 210 and 310 depicted are similar, so the same parts are marked with the same reference number. Figure 5 System 410 and Figure 2A-2B and Figure 3-4 A significant difference between systems 110, 210 and 310 is that system 410 also includes a cathode shield 170.

[0107] In a non-limiting aspect, the cathode shield 170 may be disposed between and spaced apart from the anode 160 and the cathode 180. For example, the anode 160 may be disposed between the electrolyte injection manifold 150 and the cathode shield 170. Any number of mechanical supports, brackets, or hangers 145a may be used to position the electrolyte injection manifold 150, anode 160, cathode shield 170, and cathode 180 in the bath 145 as desired.

[0108] A cathode shield 170 is disposed in an electrolytic bath 145 between an anode 160 and a cathode 180. The cathode shield 170 may define a cathode shield 171. In a non-limiting aspect, the cathode shield 171 may define a group of cathode shield orifices 176 therethrough. The cathode shield orifices 176 may be sized and oriented to receive an electrolytic fluid flow 149 therethrough. It is contemplated that the cathode shield 170 may define any number of cathode shield orifices 176 in various aspects. The cathode shield orifices 176 may be spaced apart from each other axially along the length of the cathode shield 170. For example, in a non-limiting aspect, the cathode shield orifices 176 may be spaced in a row along the axial length of the cathode shield 170. At least a subgroup of the group of cathode shield orifices 176 may be aligned with the cathode 180 (e.g., with respect to the direction of the electrolytic fluid flow 149). The group of cathode shield orifices 176 may be sized and arranged to control, direct, or guide the rate, direction, or both of the electrolytic fluid flow 149.

[0109] The cathode shield 170 may be formed of a non-conductive or ion-resistant 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, fluoropolymers (e.g., Teflon® or PVDF), etc.

[0110] In a non-limiting aspect, the electrolyte flow 149 may flow from the anode 160 to the cathode shield 170. The cathode shield 170 may partially block, impede, or deflect a portion of the electrolyte flow 149 while allowing another portion of the electrolyte flow 149 to flow around the cathode shield body 171 and / or through a group of cathode shield orifices 176 defined therein to flow to the cathode 180.

[0111] 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 electric field 193 and the current 195 passing through the electrolyte solution 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 thickness profile of the metal ions electrodeposited on the mandrel 182 can be selectively controlled, at least in part, by adjusting the electric field 193 or guiding the electrolyte flow 149, or both or a combination thereof, by constructing the size, shape, orientation, and combination thereof of the cathode shield 170 and the cathode shield orifice 176.

[0112] 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 electrolyte 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 modulated by the presence of the cathode shield 170. Furthermore, the shape, size, and position of the cathode shield body 171 within the electrolyte flow 149, as well as the size, number, and position of the cathode shield orifices 176, can affect the characteristics of the electrolyte flow 149 with respect to the cathode 180 (e.g., rate and direction).

[0113] 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 than the outer region of the cathode 180 with a shielded (e.g., shielded by the cathode shroud 170) surface area. Therefore, the electrodeposition rate (and thus the thickness profile of the electrodeposited metal) can be further controlled by shaping the cathode shroud 170 and constructing the cathode shroud orifice 176 to arrange the desired characteristics (e.g., rate and direction) of the electrolyte flow 149.

[0114] Advantageously, the system for electroformed metal components described herein allows for improved control over the thickness of electroformed metal components compared to conventional techniques. Furthermore, this method allows for the production of metal components with reduced porosity compared to conventional techniques. The reduced porosity achieved by this method can enhance the aerodynamic performance of the metal components when used as fan blade shrouds. Additionally, the system and method disclosed herein reduce anode bridging without the need for mechanical oscillators. In summary, this simplified manufacturing process reduces time, cost, and defects, and allows for comprehensive improvements in the final product compared to similar metal components formed by conventional systems, such as increased smoothness and reduced porosity.

[0115] Figure 6 A method 300 for electroplating a metal component 138 is illustrated. Unless otherwise specified, method 300 is provided for illustrative purposes and may be performed in a different logical order, or may include additional or inserted steps. Although method 300 is... Figure 2A-5 The method 300 is described in the context of systems 110, 210, 310, and 410, but in order to form metal components 138 by electrodeposition onto the mandrel 182, it can be used in a similar manner to form other types of bodies using other suitable forms.

[0116] Method 300 begins at 305, wherein an electrolyte solution 148 is disposed in a bath 145. The bath may have a fluid inlet pipe 141 and a fluid outlet pipe 143, which are fluidly connected to the electrolyte solution 148.

[0117] In a non-limiting aspect, the electrolyte 148 may comprise an aluminum alloy containing alloy metal ions. In another non-limiting example, the electrolyte 148 may comprise a nickel alloy containing 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).

[0118] Method 300 may include, at 315, immersing an electrolytic solution injection manifold 150, comprising a group of fluid injection nozzles 159, into an electrolytic solution 148 in a bath 145. In a non-limiting aspect, the electrolytic solution injection manifold 150 may include a body having at least one wall 150a arranged to define a manifold interior 158. The at least one wall 150a may further define fluid injection nozzles 159 therethrough. In a non-limiting aspect, the manifold interior 158 may define a channel for an electrolytic fluid flow 149 in fluid communication with the group of fluid injection nozzles 159.

[0119] Method 300 may further include, at 340, injecting an electrolyte solution 148 from an electrolyte solution injection manifold 150 into a bath 145 to define an electrolyte fluid flow 149 within the bath 145, the electrolyte fluid flow 149 extending from the electrolyte solution injection manifold 150 to a fluid outlet conduit 143. In a non-limiting aspect, the electrolyte fluid flow 149 may be arranged from upstream to downstream, flowing from a fluid inlet conduit 141 to the electrolyte solution injection manifold 150, and then radially outward through a group of fluid injection nozzles 159 into the bath 145, flowing toward the anode 160. For example, in a non-limiting aspect, the fluid inlet conduit 141 and the fluid outlet conduit 143 may be arranged in various ways or oriented about each other as desired, so that the electrolyte fluid flow 149 can flow from upstream to downstream, from the fluid inlet conduit 141 to the electrolyte solution injection manifold 150, to the anode 160, to the cathode 180, and to the fluid outlet conduit 143.

[0120] In a non-limiting aspect, injecting the electrolyte solution 148 from the electrolyte solution injection manifold 150 into the bath 145 may include: fluidly connecting the electrolyte solution injection manifold 150 to a fluid inlet pipe 141; and at 325, connecting a fluid pump 147 to a fluid outlet pipe 143 to receive the electrolyte solution 148 therefrom. In a non-limiting aspect, injecting the electrolyte solution 148 from the electrolyte solution injection manifold 150 into the bath 145 may also include: connecting the fluid pump 147 to a fluid inlet pipe 141 to supply the electrolyte solution 148 thereto. In some non-limiting aspects, a filter 144 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 144 may include a chemical filter medium. Optionally, a heater 146 may be provided to regulate the temperature of the electrolyte solution 148 in the bath 145. In a non-limiting example, heater 146 may be disposed within bath 145 or disposed near bath 145 outside bath 145. Alternatively, heater 146 may be in fluid communication with fluid pump 147 to heat electrolyte solution 148 when electrolyte solution 148 is pumped by fluid pump 147.

[0121] In a non-limiting aspect, injecting the electrolyte solution 148 from the electrolyte solution injection manifold 150 into the bath 145 may further include: pumping the electrolyte solution 148 from the fluid inlet pipe 141 to the electrolyte solution injection manifold 150.

[0122] Method 300 may include, at 345, positioning the anode 160 downstream of the electrolyte injection manifold 150 in a bath 145. For example, the anode 160 may be a mating anode 160 having a surface geometry that matches or complements the surface geometry of the cathode 180 (e.g., the outer mandrel surface 185a) or the surface geometry of the metal member 138 to be formed.

[0123] The anode 160 may include an anode material 160a. In some exemplary aspects, the anode material 160a may be in the form of a group of spheres, pellets, disks, cubes, sheets or any other desired geometry (including amorphous), but is not limited thereto.

[0124] 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 surface 164a facing the basket interior 167 and an opposing second outward 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 therethrough, arranged to allow an electrolyte flow 149 to enter the basket interior 167 from the exterior of the anode basket 165 and pass through or over 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 entering 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 achieve any desired properties or characteristics of the electrolyte flow 149, including the rate and direction of the electrolyte flow 149.

[0125] In a non-limiting aspect, the anode basket 165 may also include a top or cover 169. The cover 169 may define a group of second orifices 169c therethrough, the group of second orifices 169c being arranged to allow an electrolyte flow 149 to exit through it 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 169c may be selectively configured to achieve any desired characteristics or features of the electrolyte flow 149, including the rate 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 of the walls 164 may define a corresponding group of third orifices 164c therethrough to allow the electrolyte solution 148 to enter or exit, or both.

[0126] Method 300 may include, at 347, immersing a gas injection manifold 130, comprising a group of gas injection nozzles 132, into an electrolyte solution 148 in a bath 145. The gas injection manifold 130 may be immersed upstream of the cathode 180 or positioned in the electrolyte solution 148 with respect to an electrolyte flow 149. For example, in a non-limiting aspect, the gas injection manifold 130 may be positioned between the anode 160 and the cathode 180. Any number of mechanical supports or hangers 145a may be used to position the gas injection manifold 130. In a non-limiting aspect, a gas source 137 (such as an air pump or pressurized gas tank) may be fluidly coupled to the gas injection manifold 130 to supply it with gas 135 (e.g., oxygen).

[0127] Gas source 137 may be connected in fluid communication with gas inlet pipe 142 to arrange gas flow 139 of gas 135 into electrolytic solution 148 within bath 145. Gas inlet pipe 142 may be connected in fluid communication with gas injection manifold 130 to provide gas flow 139 thereto.

[0128] In a non-limiting aspect, method 300 may include, at 348, injecting gas 135 from gas injection manifold 130 into bath 145 to define a gas flow 139 within bath 145. Gas flow 139 may extend from gas injection manifold 130 to cathode 180.

[0129] In a non-limiting aspect, injecting gas 135 from gas injection manifold 130 into bath 145 may include: connecting gas injection manifold 130 to a gas inlet pipe 142 in fluid communication; and connecting gas source 137 to a gas inlet pipe 142 in fluid communication to supply gas 135 thereto. In a non-limiting aspect, injecting gas 135 from gas injection manifold 130 into bath 145 may include: pumping gas from gas inlet pipe 142 to gas injection manifold 130.

[0130] In a non-limiting aspect, the gas injection manifold 130 may be supported by the anode basket 165 and may be positioned downstream of the anode material 160a with respect to the electrolytic fluid flow 149.

[0131] In the illustrated exemplary embodiment, an anode basket cover 169 may define a recess or slot 269 therein. A gas injection manifold 130 may be disposed within the slot 269 and may be supported by the anode basket 165. A bracket or strap (not shown) may be used to hold the gas injection manifold 130 within the slot 269. In other respects, the gas injection manifold 130 may be supported by any other portion of the anode basket 165 as desired, without departing from the scope of this disclosure.

[0132] Method 300 may include, at 350, positioning the cathode 180 downstream of the anode 160 in a bath 145. In a non-limiting aspect, the cathode 180 may be a mandrel 182 having a mandrel body 185. The mandrel body 185 may have an outer mandrel surface 185a. The outer mandrel surface 185a is shaped and arranged to conform to the desired shape of the metal component 138 to be electroformed. The outer mandrel surface 185a may be formed of a conductive material (e.g., a coating). For example, in a non-limiting aspect, the conductive material may be formed of copper, silver, or nickel, without limitation. In a non-limiting aspect, the conductive material may be applied to the mandrel 182 via spraying, smearing, coating, or similar treatment to facilitate the formation of the cathode 180.

[0133] The mandrel 182 may include a mandrel body 185, which, as a non-limiting example, may be formed from a recyclable material. For example, the mandrel body 185 may be made from a 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, plastics, polymer foams, metals, or deformable materials, such as those that, in a non-limiting example, can be collected via melting or extraction. After the electroforming process is completed, the mandrel body 185 may be recycled from the electroformed component, for example, by heating and melting the mandrel body 185 at elevated temperatures to recover structural material. The mandrel 182 may define or correspond to the shape of the metal component 138.

[0134] Method 300 may include, at 355, electrically connecting a power supply 190 to an anode 160 and a cathode 180 to provide a current 195 therebetween through an electrolytic solution 148. The 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 power supply 190 is operatively capable of generating an electric field 193 across the electrolytic solution 148 between the anode 160 and the cathode 180. The current 195 may induce metal ions to move from the anode 160 to the cathode 180 and deposit onto the mandrel 182.

[0135] In a non-limiting aspect, method 300 may optionally include, at 360, disposing a cathode shield 170 in a bath 145 between the anode 160 and the cathode 180. The cathode shield 170 may be formed of a non-conductive or ion-resistant 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 can be formed by PVDF or other similar methods.

[0136] In a non-limiting aspect, the cathode shroud 170 may include a cathode shroud body 171 defining a group of cathode shroud apertures 176 therethrough. The cathode shroud apertures 176 may be sized and oriented to receive an electrolyzer flow 149 therethrough. The cathode shroud apertures 176 may be spaced apart from each other axially 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., with respect to the direction of the electrolyzer flow 149). The group of cathode shroud apertures 176 may be sized and arranged to control, direct, or guide the rate or direction, or both, of the electrolyzer flow 149.

[0137] Advantageously, the method described herein allows for improved control over the thickness of electroformed metal components compared to conventional techniques. Furthermore, the method allows for the production of metal components with reduced porosity compared to conventional techniques. The reduced porosity achieved by the method can enhance the aerodynamic performance of the metal components when used as fan blade shrouds. Additionally, the systems and methods disclosed herein reduce anode bridging without the need for mechanical oscillators. In summary, this simplified manufacturing process reduces time, cost, and defects, and allows for comprehensive improvements in the final product compared to similar metal components formed by other methods, such as improved smoothness, reduced porosity, or thickness control, and combinations thereof.

[0138] To a degree not yet described, different features and structures of the aspects can be combined and used with each other as desired. The fact that a certain feature cannot be shown in all aspects does not mean it cannot be shown, but rather that it is done for the sake of descriptive brevity. Therefore, various features of different aspects can be mixed and matched as desired 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 accompanying figures, this disclosure also contemplates many other possible aspects and constructions.

[0139] 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 significantly different 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.

[0140] 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 gas inlet conduit fluidly connected to the electrolyte solution; an anode disposed in the bath; a cathode disposed in the bath and spaced apart from the anode; an electrical power supply electrically connected to the anode and cathode to provide a current from the anode to the cathode through the electrolyte solution in the bath; a gas source connected to the gas inlet conduit in fluid communication to supply gas thereto; and a gas injection manifold disposed in the bath and connected to the gas inlet conduit in fluid communication to receive gas therefrom, the gas injection manifold including a group of gas injection nozzles configured to inject gas therefrom into the electrolyte solution in the bath to define a gas flow extending from the gas injection manifold to the cathode.

[0141] In any of the foregoing provisions, the gas injection nozzles are spaced apart from each other along the length of the gas injection manifold in the axial direction.

[0142] In any of the foregoing provisions, the anode includes an anode basket configured to support the anode material.

[0143] In any of the foregoing provisions, the anode basket is formed of a conductive material.

[0144] In any of the foregoing provisions, the gas injection manifold is connected to the anode basket.

[0145] In any of the foregoing provisions, the system wherein the anode basket defines an opening, and wherein a gas injection manifold is disposed within the opening.

[0146] In any of the foregoing provisions, the gas injection manifold is disposed between the anode and the cathode.

[0147] The system according to any of the foregoing provisions also includes a cathode shroud disposed between the anode and the cathode.

[0148] In any of the foregoing provisions, the metal component is a fan blade shroud for the fan blades.

[0149] According to any of the foregoing provisions, the system further includes a bath containing a fluid inlet pipe and a fluid outlet pipe, both fluidly connected to the electrolyte solution. The system also includes: a fluid pump connected to the fluid outlet pipe to receive the electrolyte solution therefrom and further connected to the fluid inlet pipe to supply the electrolyte solution thereto; and an electrolyte solution injection manifold fluidly connected to the fluid inlet pipe to receive the electrolyte solution therefrom, the electrolyte solution injection manifold including a group of fluid 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 being directed toward the anode and downstream toward the cathode.

[0150] According to any of the foregoing provisions, the system wherein the anode includes an anode basket configured to support an anode material, and wherein the anode basket defines a group of first orifices therethrough, which are arranged to receive an electrolyte fluid flow in fluid communication with the anode material.

[0151] A method for electroforming a metal component, the method comprising: disposing an electrolyte solution in a bath having a gas inlet conduit; immersing a gas injection manifold comprising a group of gas injection nozzles in the electrolyte solution in the bath, the manifold being in fluid communication with the gas inlet conduit to receive gas therefrom; injecting gas from the gas injection manifold into the bath to define a gas flow within the bath; disposing an anode in the bath; disposing a cathode spaced apart from the anode in the bath; and electrically connecting a power supply to the anode and cathode to provide current therebetween through the electrolyte solution.

[0152] The method according to any of the foregoing provisions, wherein the gas injection nozzles are spaced apart from each other along the length of the gas injection manifold in the axial direction.

[0153] The method described in any of the foregoing clauses, wherein the gas injection manifold is disposed between the anode and the cathode.

[0154] The method according to any of the foregoing provisions, wherein the anode includes an anode basket configured to support the anode material.

[0155] The method described under any of the foregoing clauses, wherein the anode basket is formed of a conductive material.

[0156] The method according to any of the foregoing clauses, wherein the gas injection manifold is connected to the anode basket.

[0157] The method according to any of the foregoing clauses, wherein the anode basket defines the slot, and wherein the gas injection manifold is disposed within the slot.

[0158] The method according to any of the foregoing provisions further includes: immersing an electrolyte solution injection manifold comprising a group of fluid injection nozzles into an electrolyte solution in a bath; and injecting an electrolyte solution from the electrolyte solution injection manifold into the bath to define an electrolyte solution fluid flow within the bath, the electrolyte solution fluid flow flowing toward the anode and downstream toward the cathode.

[0159] According to any of the foregoing provisions of the method, the anode basket is defined through a group of first orifices therein, which are arranged to receive an electrolyte fluid flow in fluid communication with the anode material.

Claims

1. A system for electroformed metal components, comprising: A bath configured to contain an electrolyte solution, the bath having a gas inlet pipe in fluid connection with the electrolyte solution; The anode is disposed in the bath. A cathode, which is disposed in the bath spaced apart from the anode; An electrical power supply, electrically connected to the anode and the cathode, provides current from the anode to the cathode through the electrolytic solution in the bath; A gas source, which is connected in fluid communication with the gas inlet pipe to supply gas thereto; as well as A gas injection manifold, disposed in the bath and connected in fluid communication with the gas inlet pipe to receive the gas therefrom, the gas injection manifold including a group of gas injection nozzles configured to inject the gas therefrom into the electrolyte solution within the bath to define a gas flow extending from the gas injection manifold to the cathode.

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

3. The system according to claim 1, wherein, The anode includes an anode basket configured to support 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 3, wherein, The gas injection manifold is connected to the anode basket.

6. The system according to claim 5, wherein, The anode basket defines a slot, and the gas injection manifold is disposed within the slot.

7. The system according to claim 1, wherein, The gas injection manifold is disposed between the anode and the cathode.

8. The system according to claim 1 further includes a cathode shield disposed between the anode and the cathode.

9. The system according to claim 1, wherein, The metal component is a fan blade guard for the fan blades.

10. The system according to claim 1, wherein, The bath further includes a fluid inlet pipe and a fluid outlet pipe, both of which are fluidly connected to the electrolytic solution. The system also includes: A fluid pump, connected in fluid communication with the fluid outlet pipe to receive the electrolytic solution therefrom, and further connected in fluid communication with the fluid inlet pipe to supply the electrolytic solution thereto; and An electrolyte injection manifold, fluidly connected to the fluid inlet pipe to receive the electrolyte solution therefrom, the electrolyte injection manifold including a group of fluid 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 flowing toward the anode and downstream toward the cathode.

Images