Systems and methods for cold spray additive manufacturing using a combination of superplastic forming and diffusion bonding

Abstract

To provide structural reinforcement to a workpiece by performing cold spray additive manufacture (CSAM) with superplastic formation diffusion bonding (SPFDB).SOLUTION: Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes an SPFDB component, a CSAM component, and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different order. An implementation is configured to cold-spray (with the CSAM component) an additive material onto the workpiece, and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. The cold spraying results in an increased thickness of the finished workpiece in a target region, which provides structural reinforcement and has a tapered edge. The workpiece is a metal substrate made of titanium, aluminum, stainless steel, or another material.SELECTED DRAWING: Figure 3

Description

Background Art

[0001] The manufacture of components with complex and diverse curvatures (e.g., doubly curved components that are curved in orthogonal dimensions) often requires the integration of multiple components and processes. Typically, the surface is formed by superplastic forming, hydroforming, incremental forming, or similar techniques. Unfortunately, in superplastic forming, thin regions may occur in the resulting shape. Since resulting thickness control is often difficult, current methods impose limitations on the shape and curvature of the features that can be formed. For example, in superplastic forming diffusion bonding (SPFDB), to provide reinforcement and counter thinning, sheets welded at specific locations are used to increase the thickness of the component. However, the incremental thickness is a function of the sheet thickness of the available additive, which may be larger than necessary. This restricts the configuration options and increases the weight beyond what is required when finer thickness adjustment is possible.

[0002] Abrupt termination at the edge of the added sheet not only creates an undesirable step function in the thickness of the finished component, but the welds can exhibit various superplastic behaviors that limit the options for the reinforcement (location, size, shape, etc.). Thus, incremental sheet forming can increase cost, complexity, manufacturing time, and may increase weight beyond what is necessary.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The disclosed embodiments are described in detail below with reference to the accompanying drawings listed below. The following summary is provided to explain the implementations disclosed herein. However, it is not meant to limit all examples to a specific configuration or sequence of operations.

Means for Solving the Problems

[0004] Various implementation forms are provided to fabricate a finished workpiece having a formed portion. One implementation form includes a superplastic forming diffusion bonding (SPFDB) component, a cold spray additive manufacturing (CSAM) component, and a mold having a concave surface. Various configurations can operate the SPFDB component and the CSAM component on the workpiece in different orders. One implementation form is configured to Concave surface of the mold cold spray an additive onto it, perform superplastic forming (using the SPFDB component) on the workpiece using the mold, thereby turning the workpiece into a finished workpiece having a formed portion. The formed portion conforms to the shape defined by the concave surface. The cold spray results in an increased thickness of the finished workpiece in the target area, which can provide structural reinforcement and can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or other materials.

[0005] The features, functions, and advantages considered should be achieved independently in various implementation forms or combined in further other implementation forms, and their further details can be seen with reference to the following description and drawings.

[0006] The disclosed examples are described in detail below with reference to the figures of the accompanying drawings listed below.

Brief Description of the Drawings

[0007]

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DETAILED DESCRIPTION OF THE INVENTION

[0008] Corresponding reference characters indicate corresponding parts throughout the drawings.

[0009] With reference to the accompanying drawings, various implementation forms And reference examples will be described in detail. As much as possible, the same reference numbers are used throughout the drawings to refer to the same or similar parts. References made throughout the present disclosure in connection with specific implementation forms and implementation forms are provided for illustrative purposes only and do not mean to limit all implementation forms unless otherwise indicated.

[0010] The foregoing summary, as well as the following detailed description of certain implementations, will be better understood when read in conjunction with the accompanying drawings. As used herein, elements or steps recited in the singular and preceded by the word "a" or "an" should not necessarily be construed as excluding a plurality of such elements or steps. Further, references to "one implementation" or "an implementation" are not intended to be construed as excluding the existence of additional implementations that also incorporate the recited features. Additionally, unless explicitly stated to the contrary, an implementation "comprising" or "having" an element or elements with a particular characteristic may include additional elements that do not have that particular characteristic.

[0011] Aspects of the present disclosure simplify the manufacture of complex structures by, for example, increasing the thickness of a finished workpiece (e.g., a sheet of metal such as titanium, aluminum, or stainless steel) within a target region to provide structural reinforcement, in combination with superplastic forming diffusion bonding (SPFDB) and cold spray additive manufacturing (CSAM). By implementing one or more implementations of the present disclosure, the increased thickness can be tapered at the edges, avoiding the drawbacks of a step function in thickness (e.g., unnecessary weight, surface irregularities, and concentration of mechanical stress). Further, since the increase in thickness can be adjusted to meet structural requirements, there is no longer a constraint to incrementally increase the final workpiece thickness profile according to the thickness of the available material sheet. Some implementations enable the fabrication of components that are strengthened, for example, by functionally grading a workpiece with compatible but different materials by using CSAM and / or diffusion bonding. As a result, the performance of lightweight and low-cost components is improved.

[0012] Aspects of the present disclosure reduce manufacturing steps, reduce costs, and improve the functionality of the supply chain. For example, a complex structure made of multiple parts can be unitized in one manufacturing step. For example, a finished workpiece can be a single structure with integrated stiffeners, whereas previously the stiffeners were added as individual parts or in separate processes. The stiffeners can be used, for example, within regions surrounding fasteners and other high-stress parts of the finished workpiece.

[0013] The CSAM reinforcement can generate a more complex, superior, thickness-adjusted distribution SPFDB structure, such as a thin wall if possible and a thicker wall if necessary. This allows for an optimal weight and shape while accommodating structural stress. The SPFDB uses both temperature and pressure to apply to a mold to deform a workpiece, which may thin areas of the workpiece. CSAM is used to add a thicker deposit in specific areas by stacking deposit reinforcements layer by layer as the nozzle repeatedly moves across the area, with the number of passes and the speed of the passes determining the thickness of the deposited stack. Multiple different configurations are disclosed. Aspects of the present disclosure can be used to form a sandwich structure with internal gas pockets, such as a multi-sheet SPFDB creating four sandwich structures using, for example, four workpiece sheets. CSAM may be used to form pads of additive material on at least some portions of the inside and / or outside of the sandwich structure.

[0014] Aspects and implementations disclosed herein are directed to manufacturing a finished workpiece having a formed part. One implementation includes an SPFDB component, a CSAM component, and a mold having a concave surface. Various configurations can operate the SPFDB component and the CSAM component on the workpiece in different orders. One implementation is to (using the CSAM component) add material Concave surface of the moldSpray cold on it and perform superplastic forming (using the SPFDB component) on the workpiece using a mold, thereby forming the workpiece into a completed workpiece having a formed portion. The formed portion, in some examples, conforms to a shape defined by a concave surface. The cold spray results in an increased thickness of the completed workpiece in the target area, which can provide structural reinforcement and can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or other materials.

[0015] More specifically, referring to the drawings, FIG. 1 shows a system 100 for fabricating a completed workpiece 120 by performing CSAM with an SPFDB. (Reference example) System 100 is a general representation, and variations of a plurality of specific configurations are shown in FIG. 2. System 100 takes in an unfinished workpiece 110 and uses a mold 150 (also referred to as a “die” in some contexts) to turn the unfinished workpiece 110 into a completed workpiece 120. In some shape instances, the unfinished workpiece 110 comprises a metal substrate (e.g., a metal sheet) having a metal selected from the list consisting of titanium, aluminum, and stainless steel. Both the CSAM component 300 and the SPFDB component function on the unfinished workpiece 110. The CSAM component 300 takes in the CSAM material 301, and the SPFDB component 400 takes in the SPFDB material 401.

[0016] The CSAM component 300 (from the CSAM material 301) cold sprays an additive 303 onto the unfinished workpiece 110. The cold spray of the additive 303 results in an increase in the thickness of the completed workpiece 120 in the target area 124. This can provide structural reinforcement of the completed workpiece 120 in the target area 124 and can also provide a functionally graded material, which is described in more detail in connection with FIG. 3. As described in more detail in connection with FIG. 4, the SPFDB component 400 performs superplastic forming on the unfinished workpiece 110 using the mold 150.

[0017] Next, turning to FIG. 2, various configurations 200a - 200d of the system 100 are shown. In the case of configuration 200a (Reference example) , the CSAM component 300 sprays the additive 303 onto the unfinished workpiece 110 in such a way that when the SPFDB component 400 uses the mold 150 to shape the unfinished workpiece 110 into the shape of the finished workpiece 120, the resulting finished workpiece 120 has the desired thickness profile. The step of changing the unfinished workpiece 110 into the finished workpiece 120 using configuration 200a is shown in FIG. 5. In the case of configuration 200b, the CSAM component 300 sprays the additive 303 onto the mold 150, and then the SPFDB component 400 uses the mold 150 to shape the unfinished workpiece 110 into the shape of the finished workpiece 120 while performing diffusion bonding with the additive 303. The resulting finished workpiece 120 has the desired thickness profile. The step of changing the unfinished workpiece 110 into the finished workpiece 120 using configuration 200b is shown in FIG. 7.

[0018] In the case of configuration 200c (Reference example) , the SPFDB component 400 uses the mold 150 to shape the unfinished workpiece 110 into an approximate shape of the finished workpiece 120, and then the CSAM component 300 sprays the additive 303 onto the unfinished workpiece 110 to make it into the finished workpiece 120 having the desired thickness profile. The step of changing the unfinished workpiece 110 into the finished workpiece 120 using configuration 200c is shown in FIG. 9. In the case of configuration 200d, the CSAM component 300 sprays the additive 303 onto the mold 150a (or mold 150), and then the SPFDB component 400 uses the mold 150a (or mold 150) to shape the unfinished workpiece 110 into the shape of the finished workpiece 120 while diffusion bonding it to the additive 303. The resulting finished workpiece 120 has the desired thickness profile. The step of changing the unfinished workpiece 110 into the finished workpiece 120 using configuration 200d is shown in FIG. 11.

[0019] Figure 3 shows one Reference example of the CSAM components 300, which includes a cold spray apparatus 302 that can be used to cold spray an additive 303 onto a workpiece 110 in progress to form a deposit 370. The additive 303 can be in powder form of the same material as the workpiece in progress (e.g., titanium or aluminum), or it can be a different material for functional grading. A gas source 307, such as nitrogen or helium, is connected to a gas control module 306 via an inlet 308. The CSAM material 301 includes the additive 303 and the gas 307. The gas control module 306 controls the flow of the gas 307 through a first line 314 connected to a nozzle 304 and through a second line 316 connected to a powder chamber 318, and then reaches the nozzle 304. The gas 307 flowing through the lines 314 and 316 causes the additive 303 disposed in the powder chamber 318 to be sprayed as a particle stream 305 from the nozzle 314. The particle stream 305 moves at high speed from a nozzle 304, which can be a supersonic nozzle in one example, and is deposited on the surface of the workpiece 110 in progress to form a deposit 370. The particle stream 305 is sprayed at a temperature well below the melting point of the additive 303. When the particles of the particle stream 305 collide with the workpiece 110 in progress, they undergo plastic deformation due to the high speed of the particle stream 305, bond to each other, and bond to the workpiece 110 in progress to increase the thickness of the workpiece 110 in progress.

[0020] The cold spray apparatus 302 includes, in one example, a heater 310 that is used to heat the gas 307 to the required temperature before the gas 307 enters the nozzle 304. For example, the gas 307 is heated between 400 degrees Celsius and 900 degrees Celsius before entering the nozzle 304 so that the additive 303 can be sprayed as the particle stream 305. The heater 310 is used to accelerate the speed of the particle stream 305, but the heat from the heated gas 307 is not transferred to the metallurgical bonding of the particles of the particle stream 305.

[0021] One Reference exampleIn this case, the additive 303 used in the cold spray process is configured to produce a desired thickness on the unfinished workpiece 110, as would be recognized by one of ordinary skill in the art having the advantages of the present disclosure. In contrast to thermal spraying, cold spraying of the additive 303 can enable the use of a larger amount of the additive 303 to produce a desired thickness. The additive 303 can be a mixture of materials to create the desired structural reinforcement and other properties in the finished workpiece 120. For example, the additive 303 can include nickel powder, cobalt powder, and iron powder. The use of cold spraying helps to strengthen the finished workpiece 120 and reduce distortion due to thermal and mechanical stresses.

[0022] One Reference example In this case, the CSAM component 300 includes a robot control system 330 that controls a robot positioning arm 332 to move the cold spray device 302 relative to the unfinished workpiece 110. By moving the cold spray device 302, the nozzle 304 moves relative to the unfinished workpiece 110, and as a result, the particle stream 305 creates a thinner or thicker portion of the deposit 370. For example, if the nozzle 304 remains at a first location longer than it remains at a second location or passes through a first location more than it passes through a second location, the deposit 370 will be thicker at the first location. In this way, the deposit 370 can have a tapered edge rather than a sharp edge (e.g., a step function edge). One Reference example In this case, the robot positioning arm 332 moves the unfinished workpiece 110 rather than the cold spray device 302. One Reference example In this case, two robot positioning arms 332 move both the unfinished workpiece 110 and the cold spray device 302. One Reference example In this case, the robot control system 330 is at least partially controlled by one or more processors 1819 of the computing device 1800 of FIG. 18 executing instructions. One Reference example In this case, the robot control system 330 is one of the computing device 1800 Reference exampleincludes. In one Reference example example, the components of the cold spray apparatus 302 (e.g., the gas control module 306 and the heater 310) are controlled by a computing device 1800. Reference example

[0023] FIG. 4 shows one implementation of the SPFDB component 400, which includes an SPFDB apparatus 402 that can be used to perform superplastic forming to shape the unfinished workpiece 110 and diffusion bonding to bond material to the unfinished workpiece 110. Specifically, the SPFDB apparatus 402 shapes the unfinished workpiece 110 to fit into the mold 150, which is shown as having a concave surface 152. A lid 410 is placed over the forming chamber 412 to clamp the unfinished workpiece 110 between the lid 410 and the forming chamber 412. The unfinished workpiece 110 is heated to the superplastic temperature using a heater 422.

[0024] The gas source 407 is connected to the gas control module 406 via an inlet 408. When the unfinished workpiece 110 reaches the superplastic temperature, a gas 407 that can dry argon is injected under pressure through an inlet line 414 and a passage 418 in the lid 410 to pressurize the space between the underside of the lid 410 and the unfinished workpiece 110. The pressure of the gas 407 acting on the unfinished workpiece 110 deforms the unfinished workpiece 110 to fit into the concave surface 152 of the mold 150. The pressure can be moved from the forming chamber 412 through a second gas line 416 and a passage 420 in the forming chamber 412. When the fitting operation for the unfinished workpiece 110 to match the concave surface 152 of the mold 150 is completed, the forming pressure of the gas 407 is reduced, the lid 410 is loosened, and the workpiece is removed from the forming chamber 412. In one implementation, a backpressure (e.g., using the gas 407) is applied through the second gas line 416 and the passage 420. As shown in FIG. 2D, after the metal blank 58 is fully formed against the opposing surface of the die 56, the pressure in channel A is returned to the magnitude of the pressure in channel B, and then the pressures in both channels A and B are reduced according to the decreasing schedule shown in zone C of FIG. 4.

[0025] The SPFDB material 401 includes a release agent 403 and a gas 407. In one implementation, the release agent 403 is added to facilitate the removal of the finished workpiece 120 from the mold 150 (or the unfinished workpiece 110, depending on whether SPFDB is the final process step). In one implementation, the SPFDB component 400 includes an implementation of a computing device 1800 that controls the components of the SPFDB apparatus 402 (e.g., the gas control module 406 and the heater 422).

[0026] As shown in FIG. 2, FIG. 5 shows steps 501-503 of transforming the unfinished workpiece 110 into the finished workpiece 120 using the configuration 200a of the system 100. The unfinished workpiece 110 has an opposing side 111 and a back side 112 that are disposed relative to the mold 150. The mold 150 has a concave surface 152. Although only a two-dimensional (2D) profile is shown, it should be understood that the concave surface 152 within the mold 150 may be doubly curved, curving in orthogonal dimensions. For example, the concave surface 152 shown in 2D may be a semi-circle in three dimensions (3D), and the concave surface may be hemispherical. In step 501, the unfinished workpiece 110 has not yet been adapted to conform to the concave surface 152 of the mold 150, and the unfinished workpiece 110 has not been exposed to cold spray.

[0027] In step 502, the additive 303 is cold sprayed onto the unfinished workpiece 110 to form a deposit 370 within the target region 124. It should be understood that the deposit 370 may be on either, or both, of the opposing side 111 and the back side 112 of the unfinished workpiece 110. As shown, the target region 124 extends over a portion of the unfinished workpiece 110 that will match the concave surface 152 of the mold 150. In step 503, the unfinished workpiece 110 is reformed by superplastic forming into the finished workpiece 120 having a formed portion 122. As shown, the target region 124 extends over the entire formed portion 122, but it should be understood that this is for illustrative purposes only. In some Reference example cases, at least a portion of the target region 124 may overlap at least a portion of the formed portion 122, such that the formed portion 122 includes the entire target region 124 and may extend beyond the target region 124, the target region 124 may extend over the entire formed portion 122 and may extend beyond the formed portion 122, and the target region 124 and the formed portion 122 may partially overlap.

[0028] One Reference exampleIn this case, the increased thickness left by the deposit 370 provides structural reinforcement of the finished workpiece 120 in the target region 124. Also, as shown, the increased thickness of the finished workpiece 120 in the target region 124 tapers at the edge 126 of the target region 124. For illustrative purposes, a sharp edge 128 that creates a step function in the thickness of the finished workpiece 120 is also shown. In one Reference example In this case, the system 100 has the advantageous ability to avoid sharp edges and generate tapered edges, which is preferred in some scenarios.

[0029] FIG. 6 is a flowchart 600 showing a method of fabricating the finished workpiece 120 as shown in steps 501 - 503 of FIG. 5 using the configuration 200a of FIG. 2 (Reference example) This is the case. Operation 602 includes receiving the requirements of the finished workpiece 120, such as the shape and thickness profile, and the material to be used for the additive 303. Operation 604 includes controlling the temperatures of the unfinished workpiece 110, the gas 307, and the additive 303. In one Reference example In this case, the unfinished workpiece 110 comprises a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel.

[0030] Operation 606 includes cold spraying the additive 303 onto the unfinished workpiece 110. In one Reference example In this case, the cold spray uses helium or nitrogen gas. Operation 608 includes positioning the unfinished workpiece 110 on the mold 150 having the concave surface 152. Operation 610 includes controlling the temperatures of the unfinished workpiece 110, the mold 150, and the gas 407. Operation 612 includes superplastic forming the unfinished workpiece 110 into the finished workpiece 120 having the formed portion 122, where the formed portion 122 conforms to the shape defined by the concave surface 152. Operation 614 includes removing the finished workpiece 120 from the mold 150. In one Reference exampleThen, removing the completed workpiece 120 from the mold 150 includes removing the completed workpiece 120 from the mold 150 using a release agent 403. One Reference example Then, removing the completed workpiece 120 from the mold 150 includes, for example, using backpressure via a second gas line 416 and a passage 420.

[0031] The cold spray of the additive 303 in operation 606 resulted in an increase in the thickness of the completed workpiece 120 in the target area 124. One Reference example Then, at least a part of the target area 124 overlaps at least a part of the formed part 122. One Reference example Then, the increased thickness of the completed workpiece 120 in the target area 124 tapers at the edge 126 of the target area 124. One Reference example Then, the formed part 122 is doubly curved. One Reference example Then, the increase in thickness provides structural reinforcement of the completed workpiece 120 in the target area 124.

[0032] FIG. 7 shows steps 701 - 703 of changing the unfinished workpiece 110 into the completed workpiece 120 using the configuration 200b of the system 100 as shown in FIG. 2. In step 701, the unfinished workpiece 110 is not yet adapted to match the concave surface 152 of the mold 150, and the unfinished workpiece 110 is not exposed to the cold spray. In step 702, the additive 303 is cold sprayed within the concave surface 152 onto the mold 150 to form a deposit 372. In step 703, the unfinished workpiece 110 is reformed by superplastic forming and thus becomes the completed workpiece 120 having the formed part 122. As shown, the target area 124 extends to the part of the formed part 122 corresponding to the position of the deposit 372. The additive 303 of the deposit 372 is diffusion bonded to the unfinished workpiece 110 (now the completed workpiece 120). The position, thickness, and edge of the target area 124 can be controlled as described above.

[0033] FIG. 8 is a flowchart 800 showing a method of fabricating a finished workpiece 120 as shown in stages 701 - 703 of FIG. 7 using the configuration 200b of FIG. 2. Operation 802 includes receiving requirements for the finished workpiece 120, such as shape and thickness profile, and the material to be used for the additive 303. Operation 804 includes controlling the temperatures of the mold 150, the gas 307, and the additive 303. Operation 806 includes cold spraying the additive 303 onto the mold 150 having the concave surface 152. In one implementation, the cold spray uses helium or nitrogen gas.

[0034] Operation 808 includes positioning the unfinished workpiece 110 onto the mold 150. In one implementation, the unfinished workpiece 110 comprises a metal substrate having a metal selected from a list consisting of titanium, aluminum, and stainless steel. Operation 810 includes controlling the temperatures of the unfinished workpiece 110, the mold 150, the deposit 372, and the gas 407. Operation 812 includes superplastic forming the unfinished workpiece 110 and diffusion bonding the cold-sprayed additive 303 (as the deposit 372) to the unfinished workpiece 110, thereby converting the unfinished workpiece 110 into a finished workpiece 120 having a formed portion 122, where the formed portion 122 conforms to the shape defined by the concave surface 152. Operation 814 includes removing the finished workpiece 120 from the mold 150. In one implementation, removing the finished workpiece 120 from the mold 150 includes using a release agent 403 to remove the finished workpiece 120 from the mold 150. In one implementation, removing the finished workpiece 120 from the mold 150 includes using backpressure, for example, via a second gas line 416 and passage 420.

[0035] The cold spray of additive 303 in operation 806 results in an increase in the thickness of the finished workpiece 120 in the target area 124. In one implementation, at least a portion of the target area 124 overlaps at least a portion of the formed portion 122. In one implementation, the increased thickness of the finished workpiece 120 in the target area 124 tapers at the edge 126 of the target area 124. In one implementation, the formed portion 122 is doubly curved. In one implementation, the increase in thickness provides structural reinforcement of the finished workpiece 120 in the target area 124.

[0036] FIG. 9 shows the stage of changing the unfinished workpiece 110 into the finished workpiece 120 using the configuration 200c of the system 100 as shown in FIG. 2. (Reference example) . In step 901, the unfinished workpiece 110 is not yet adapted to match the concave surface 152 of the mold 150, and the unfinished workpiece 110 is not exposed to cold spray. In step 902, the unfinished workpiece 110 is reformed by superplastic forming to match the mold 150 and has a formed portion 122. In step 903, the additive 303 is cold sprayed onto the unfinished workpiece 110, either on the convex surface or the concave surface, or both. The cold spray turns the unfinished workpiece 110 into the finished workpiece 120. The position, thickness, and edge of the target area 124 can be controlled as described above.

[0037] FIG. 10 is a flowchart 1000 showing a method of manufacturing the finished workpiece 120 as shown in steps 901 - 903 of FIG. 9 using the configuration 200c of FIG. 2. (Reference example) . Operation 1002 includes receiving the requirements of the finished workpiece 120, such as the shape and thickness profile, and the material to be used for the additive 303. Operation 1004 includes positioning the unfinished workpiece 110 on the mold 150 having the concave surface 152. One Reference exampleIn this case, the unfinished workpiece 110 comprises a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel. Operation 1006 includes controlling the temperatures of the unfinished workpiece 110, the mold 150, and the gas 407.

[0038] Operation 1008 includes superplastic forming the unfinished workpiece 110 into a finished workpiece 120 having a formed portion 122, and the formed portion 122 conforms to the shape defined by the concave surface 152. Operation 1010 includes removing the unfinished workpiece 110 from the mold 150. One Reference example In this case, removing the unfinished workpiece 110 from the mold 150 includes using a release agent 403 to remove the unfinished workpiece 110 from the mold 150. One Reference example In this case, removing the unfinished workpiece 110 from the mold 150 includes using backpressure, for example, via a second gas line 416 and a passage 420.

[0039] Operation 1012 includes controlling the temperatures of the unfinished workpiece 110, the gas 307, and the additive 303. Operation 1014 includes cold spraying the additive 303 onto the unfinished workpiece 110. One Reference example In this case, the cold spraying uses helium or nitrogen gas. The cold spraying of the additive 303 in operation 1014 results in an increase in the thickness of the finished workpiece 120 in the target region 124. One Reference example In this case, at least a part of the target region 124 overlaps at least a part of the formed portion 122. One Reference example In this case, the increased thickness of the finished workpiece 120 in the target region 124 tapers at the edge 126 of the target region 124. One Reference example In this case, the formed portion 122 is doubly curved. One Reference example In this case, the increase in thickness provides structural reinforcement of the finished workpiece 120 in the target region 124.

[0040] As shown in FIG. 2, FIG. 11 shows the stage of transforming the unfinished workpiece 110 into the finished workpiece 120 using the configuration 200d of the system 100. In step 1101, the unfinished workpiece 110 has not yet been exposed to cold spray or superplastic forming. A mold 150a with a concave surface 152a is shown. The additive 303 is cold sprayed onto the mold 150a within the concave surface 152 to form a deposit 376, although the mold 150 can also be used for this purpose instead. Further, a mold 150b with a concave surface 152b used to form the unfinished workpiece 110 is shown, although the mold 150 can also be used for this purpose instead.

[0041] In step 1102, the deposit 376 (including the additive 303) is transferred from the mold 150a to the mold 150b. In one implementation, the concave surface 152a is sufficiently similar in shape to the concave surface 152b to form the deposit 376. In one implementation, the additive 303 is cold sprayed directly onto the mold 150b rather than being first sprayed onto the mold 150a and then moved. In one implementation, the mold 150 is used instead of the molds 150a and 150b. In step 1103, the unfinished workpiece 110 is reformed by superplastic forming and diffusion bonded to the deposit 376 at the point 130. This results in the unfinished workpiece 110 being transformed into the finished workpiece 120 having the formed portion 122 (which was the deposit 376 in this scenario). This results in an extended length 132 of the finished workpiece 120 that is longer than the length 134 of the unfinished workpiece 110 by the length 136 provided by the deposit 376. The position, thickness, and edges of the target region 124 can be controlled as described above.

[0042] FIG. 12 is a flowchart 1200 showing a method of fabricating a finished workpiece 120 as shown in stages 1101 - 1103 of FIG. 11 using the configuration 200d of FIG. 2. Operation 1202 includes receiving requirements of the finished workpiece 120, such as shape and thickness profile, and the material to be used for the additive 303. Operation 1204 includes controlling the temperatures of the mold 150a, the gas 307, and the additive 303. Operation 1206 includes cold spraying the additive 303 onto the mold 150a having the concave surface 152a. In one implementation, the cold spraying uses helium or nitrogen gas.

[0043] Operation 1208 includes positioning the unfinished workpiece 110 onto the mold 150b and disposing the cold - sprayed additive 303 (e.g., deposit 376) onto the mold 150b. In one implementation, disposing the cold - sprayed additive 303 onto the mold 150b includes disposing the cold - sprayed additive 303 within the concave surface 152b. In one implementation, disposing the cold - sprayed additive 303 onto the mold 150b includes cold - spraying the additive 303 onto the mold 150b (instead of the mold 150a). In one implementation, the unfinished workpiece 110 comprises a metal substrate having a metal selected from a list consisting of titanium, aluminum, and stainless steel.

[0044] Operation 1210 includes controlling the temperatures of the workpiece 110, the mold 150, the deposit 372, and the gas 407. Operation 1212 superplastically forms the workpiece 110 and diffusion bonds the cold-sprayed additive 303 (as deposit 376) to the workpiece 110, thereby turning the workpiece 110 into a finished workpiece 120 having a formed portion 122, where the formed portion 122 conforms to the shape defined by the concave surface 152. Operation 1214 includes removing the finished workpiece 120 from the mold 150. In one implementation, removing the finished workpiece 120 from the mold includes using a release agent 403 to remove the finished workpiece 120 from the mold 150. In one implementation, removing the finished workpiece 120 from the mold 150 includes using backpressure, for example, via a second gas line 416 and passage 420.

[0045] The cold spraying of the additive 303 in operation 1206 results in an extended length 132 of the finished workpiece 120 relative to the length 134 of the workpiece. In one implementation, the cold-sprayed additive 303 (e.g., deposit 376) has a tapered edge. In one implementation, the formed portion 122 is doubly curved. In one implementation, the increase in thickness provides structural reinforcement of the finished workpiece 120 in the target region 124.

[0046] FIG. 13 is a flowchart 1300 showing another method of fabricating a completed workpiece 120. In one implementation, operation 1302 includes receiving requirements for the completed workpiece 120, such as shape and thickness profiles, as well as the material to be used for the additive 303. A particular configuration, such as one of configurations 200a - 200d of system 100, is selected at operation 1304. At operation 1306, components of system 100, such as CSAM component 300 and SPFDB component 400, are configured according to the selection made at operation 1304. An unfinished workpiece 110 is received at operation 1308. An appropriate one of flowcharts 600, 800, 1000, and 1200 is executed as operation 1310 to fabricate the completed workpiece 120 (e.g., turn the unfinished workpiece 110 into the completed workpiece 120).

[0047] Having described the various operations of the various configurations 200a - 200d in this way and referring again to FIG. 1, the system 100 is a system for fabricating a finished workpiece 120 having a formed portion 122. The system 100 includes an SPFDB component 400, a CSAM component 300, and a mold 150 having a concave surface 152. In this case, the system 100 takes in an unfinished workpiece 110, uses the CSAM component 300 to cold spray an additive 303 onto the unfinished workpiece 110, and uses the SPFDB component 400 to perform superplastic forming on the unfinished workpiece 110 using the mold 150, thereby converting the unfinished workpiece 110 into a finished workpiece 120 having a formed portion 122. The formed portion 122 is configured to match the shape defined by the concave surface 152. In one implementation, the unfinished workpiece 110 comprises a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel. In one implementation, the cold spraying of the additive 303 results in an increase in the thickness of the finished workpiece 120 in the target region 124. In one implementation, at least a portion of the target region 124 overlaps at least a portion of the formed portion 122. In one implementation, the increase in thickness provides structural reinforcement of the finished workpiece 120 in the target region 124. In one implementation, the increased thickness of the finished workpiece 120 in the target region 124 tapers at the edge 128 of the target region 124. In one implementation, the formed portion 122 is doubly curved. In one implementation, the cold spray uses helium or nitrogen gas. In one implementation, removing the finished workpiece 120 from the mold 150 includes using a release agent 403 to remove the finished workpiece 120 from the mold 150.

[0048] FIG. 14 shows an arrangement 1400 of a multi-sheet SPFDB for forming a sandwich structure 1402 with internal pockets 1404a - 1404d. Two workpieces, namely workpiece 110a and workpiece 110b, are joined at seams 1412a, 1412b, and 1412c. A gas line 1410 provides pressure to inflate the internal pockets 1404a - 1404d, thereby generating the sandwich structure 1402. In some implementations, argon is used to minimize oxidation of workpieces 110a and 110b, or other undesirable interactions that may occur at the temperatures required for superplastic forming of workpieces 110a and 110b into the sandwich structure 1402.

[0049] FIG. 15 shows a four-sandwich structure 1500 using the sandwich structure 1402 as a core. The sandwich structure 1500 has a surface layer 1501 (made from workpiece 110c), a first core layer 1502 (made from workpiece 110a of FIG. 14), a second core layer 1503 (made from workpiece 110b of FIG. 14), and a second surface layer 1504 (made from workpiece 110d). The sandwich structure 1500 can provide enhanced structural strength and noise reduction compared to flat portions (without internal pockets 1404a - 1404d) made of the same four materials. In some implementations, a second gas line 1510 is provided during the SPFDB process to inflate regions 1512 between the core layer 1502 and the surface layer 1501, and between the core layer 1503 and the surface layer 1504.

[0050] FIG. 16 shows options for forming additive pads 1602-1618 on at least some portions of the inner and / or outer sides of the sandwich structure 1500 using CSAM. The increased thickness of the additives (e.g., additive pads 1602-1618) provides structural reinforcement of the sandwich structure 1500. For example, additive pad 1602 is outside of surface layer 1501 over at least a portion of where there is a pocket (gap) between surface layer 1501 and core layer 1502. This may be repeated for other pocket locations. Additive pad 1604 is inside of surface layer 1501 over at least a portion of where there is a pocket between surface layer 1501 and core layer 1502. This may be repeated for other pocket locations. Additive pad 1606 is outside of surface layer 1501 over at least a portion of where there is a diffusion bond between surface layer 1501 and core layer 1502. This may be repeated for other diffusion bond locations. Additive pad 1608 is inside of surface layer 1501 over at least a portion of where there is a diffusion bond between surface layer 1501 and core layer 1502. This may be repeated for other diffusion bond locations. The positions of the pads described in this way for surface layer 1501 may be replicated at equivalent positions of surface layer 1504 (compared to core layer 1503).

[0051] The additive pads 1612 are located outside the core layer 1503 (with respect to the sandwich structure 1402) over at least a portion of the locations where there are pockets between the surface layer 1504 and the core layer 1503. This may be repeated for other pocket locations. The additive pads 1614 are located inside the core layer 1503 (with respect to the sandwich structure 1402) over at least a portion of the locations where there are pockets between the surface layer 1504 and the core layer 1503. This may be repeated for other pocket locations. The additive pads 1616 are located outside the core layer 1503 over at least a portion of the locations where there are diffusion bonds between the surface layer 1504 and the core layer 1503. This may be repeated for other diffusion bond locations. The additive pads 1618 are located inside the core layer 1503 over at least a portion of the locations where there are diffusion bonds between the surface layer 1504 and the core layer 1503. This may be repeated for other diffusion bond locations. The positions of the pads thus described for the surface layer 1504 may be replicated at equivalent positions of the surface layer 1501 (with respect to the core layer 1502). The positions of some pads may provide more favorable performance than the positions of other pads. Further, the pads of the additives 1602 - 1618 may be wider or narrower than shown with respect to other features shown in the sandwich structure 1500. The additive pads 1602 - 1618 represent all pads that can be replicated on the sandwich structure 1500 at corresponding positions related to the pocket and diffusion bond locations.

[0052] Figure 17 is a flowchart 1700 showing a method of fabricating the sandwich structure 1500 using both SPFDB and CSAM. (Reference example). In operation 1702, CSAM is performed such that at least one of the additive pads 1604, 1608, 1612, 1614, 1618, and 1618 disappears after the SPFDB process of operation 1704. Thus, operation 1702 includes cold spraying an additive onto at least one of the plurality of workpieces 110a - 110d used in a sandwich structure (e.g., sandwich structure 1402 or 1500). In one Reference example instance, cold spraying uses helium or nitrogen gas.

[0053] In one Reference example instance, the sandwich structure 1500 is formed in a single SPFDB operation 1704. In one Reference example instance, the sandwich structure 1402 is formed in the first SPFDB operation 1704, allowing the addition of additive pads 1612 and 1616 in the second pass operation 1702, and then, in the second SPFDB operation 1704, the sandwich structure 1500 is formed using the sandwich structure 1402. Thus, operation 1704 includes superplastic forming and diffusion bonding the plurality of workpieces 110a - 110d to the sandwich structure 1402 or 1500. In one Reference example instance, the sandwich structure 1500 includes four sandwich structures.

[0054] In operation 1706, the CSAM process is performed on the formed sandwich structure 1500 to add additive pads 1602 and 1606, although the additive pads 1602 and 1606 may alternatively be formed in operation 1702. If only the additive pads 1602 and 1606 (and other pads in corresponding positions) are used, operation 1702 is optional. Thus, at least one of operations 1702 and 1706 should be performed, although each of operations 1702 and 1706 is optional. Operation 1706 includes cold spraying an additive onto a sandwich structure (e.g., the sandwich structure 1500 formed in one operation 1704 or in two-pass operation 1704).

[0055] Thus, aspects of the present disclosure may be used in a multi-sheet SPFDB for forming a sandwich structure with an internal pocket to create, for example, four sandwich structures (e.g., sandwich structure 1500) using four workpiece sheets. CSAM may be used to form pads on at least some portions inside and / or outside the sandwich structure 1500, such as inside or outside the surface layers 1501 and 1504 and / or inside or outside the core layers 1502 and 1503.

[0056] Referring now to FIG. 18, a block diagram of a computing device 1800 suitable for implementing various aspects of the present disclosure is described. In some implementations, the computing device 1800 includes one or more processors 1819 that execute an operating system 1820 and application software 1821 held in a memory 1822. The disclosed implementations related to the computing device 1800 are implemented by various computing devices including personal computers, laptops, smartphones, mobile tablets, handheld devices, household appliances, special computing devices, and the like. Among categories such as "workstation", "server", "laptop", "handheld device", etc., these are not distinguished when all are contemplated within the scope of the reference to "computing device" in FIG. 18 and this specification. The disclosed implementations are also implemented in a distributed computing environment where tasks are executed by remote processing devices linked via a communication network. Further, although the computing device 1800 is depicted as a single device at first glance, in one implementation, multiple computing devices operate together and share the depicted device resources. For example, in one implementation, the memory 1822 is distributed across multiple devices and the provided processors 1819 are housed on different devices.

[0057] In one implementation, memory 1822 includes any of the computer-readable media described herein. In one implementation, memory 1822 is used to store and access instructions configured to perform the various operations disclosed herein. In some implementations, memory 1822 includes computer storage media in the form of volatile and / or non-volatile memory, removable or non-removable memory, data disks within a virtual environment, or combinations thereof. In one implementation, processor 1819 includes any number of processing units that read data from various entities such as memory 1822, communication interface 1823, or input / output (I / O) controller 1824. Specifically, processor 1819 is programmed to execute computer-executable instructions for implementing aspects of the present disclosure. In one implementation, the instructions are executed by multiple processors 1819 within computing device 1800 or by a processor 1819 external to computing device 1800.

[0058] The communication interface 1823 enables the computing device 1800 to be logically coupled to other devices, which can be public or private and use various protocols, via, for example, a wired or wireless network. The I / O controller 1824 provides an output 1825 and an input 1826 that enable the operation and control of the computing device 1800. Those skilled in the art will understand and recognize that computer data can be presented in several ways, such as visually via a graphical user interface (GUI), auditorily through a speaker, and via a wireless or wired connection to a peripheral device. Those skilled in the art will also understand and recognize that computer input can be received in many ways, such as via a microphone, keyboard or keypad, mouse or other pointing device, and touch screen. Although described in relation to the computing device 1800, the implementations of the present disclosure can be implemented in many other general-purpose or special-purpose computing system environments, configurations, or devices.

[0059] Some examples of the present disclosure are shown and described in relation to FIGS. 19-21 and are used in manufacturing and service applications. Accordingly, the implementations of the present disclosure are described in the context of the apparatus of the manufacturing and service method 1900 shown in FIG. 19 and the apparatus 2000 shown in FIG. 20. FIG. 19 depicts a block diagram showing a manufacturing and service method 1900 of an apparatus according to one implementation. In one implementation, during pre-manufacture, the manufacturing and service method 1900 of the apparatus includes the specification and design 1902 and material procurement 1904 of the apparatus 2000 of FIG. 20. During manufacture, the manufacture 1906 and system integration 1908 of the components and sub-assemblies of the apparatus 2000 of FIG. 20 are performed. Thereafter, the apparatus 2000 of FIG. 20 undergoes certification and shipping 1910 for use during deployment 1912. During deployment by the customer, the apparatus 2000 of FIG. 20 is scheduled for routine maintenance and inspection 1914, which, in one implementation, includes modifications, reconfigurations, repairs, and other maintenance or services that are the subject of configuration management described herein.

[0060] In one implementation, each of the processes of manufacturing and service method 1900 of the device is performed or implemented by a system integrator, a third party, and / or an operator. In these implementations, the operator is the customer. For the purposes of this description, the system integrator includes any number of device manufacturers and subcontractors of major systems, the third party includes any number of vendors, subcontractors, and suppliers, and in one implementation, the operator is the owner of the device or a fleet of devices, the manager responsible for the device or a fleet of devices, the user operating the device, a leasing company, a military organization, a service organization, etc.

[0061] Referring now to FIG. 20, the device 2000 will be described. As shown in FIG. 20, an example of the device 2000 is an aircraft device 2001 such as an aerospace vehicle, an aircraft, an air cargo, or a flying vehicle. As also shown in FIG. 20, a further example of the device 2000 is a ground transportation device 2002 such as an automobile, a truck, a heavy machine, a construction machine, a boat, a ship, or a submarine. A further example of the device 2000 shown in FIG. 20 is a modular device 2003 including at least one or more of the following modules, namely an air module, a payload module, and a ground module. The air module provides an air transportation or flight function. The payload module provides a function of transporting objects such as cargo or living things (people, animals, etc.). The ground module provides a function of moving on the ground. The solutions disclosed herein are applied individually to each module or in groups such as the air module and the payload module, or the payload module and the ground module, or all of the modules.

[0062] Reference is now made to FIG. 21, which shows a more specific view of an aircraft 2001 in which embodiments of the present disclosure are advantageously used. In this example, the aircraft 2001 is an aircraft manufactured by the apparatus manufacturing and service method 1900 of FIG. 19 and includes an airframe 2102 having a plurality of systems 2104 and an interior 2106. Implementations of the plurality of systems 2104 include one or more of a propulsion system 2108, an electrical system 2110, a hydraulic system 2112, and an environmental system 2114. However, other systems are candidates for inclusion as well. Although an aerospace example is shown, various advantageous implementations are applicable to other industries such as the automotive industry.

[0063] The implementations disclosed herein are described in the general context of computer code or machine-usable instructions, including computer-executable instructions, such as program components, executed by a computer or other machine, such as a personal data assistant or other handheld device. Generally, program components include routines, programs, objects, components, data structures, etc., which refer to code that performs particular tasks or code that implements particular abstract data types. The disclosed implementations are implemented in a variety of system configurations, including personal computers, laptops, smartphones, mobile tablets, handheld devices, consumer electronics, special computing devices, etc. The disclosed implementations are also implemented in a distributed computing environment where tasks are performed by remote processing devices linked through a communication network.

[0064] The following paragraphs describe further aspects of the disclosure, A1. A system for fabricating a finished workpiece having a formed part, the system comprising: a superplastic forming diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; a mold having a concave surface; and the system is configured to receive an unfinished workpiece, Using a CSAM component, a cold spray of an additive is applied onto a workpiece in progress, using an SPFDB component, superplastic forming is performed on the workpiece in progress using a mold, thereby turning the workpiece in progress into a completed workpiece having a formed part, and the formed part matches the shape defined by the concave surface A system configured as such. A2. The system of A1, wherein the workpiece in progress comprises a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel. A3. The system of A1, wherein the cold spray of the additive results in an increase in the thickness of the completed workpiece in the target area. A4. The system of A3, wherein at least a part of the target area overlaps at least a part of the formed part. A5. The system of A3, wherein the increased thickness provides structural reinforcement of the completed workpiece in the target area. A6. The system of A3, wherein the increased thickness of the completed workpiece in the target area tapers at the edge of the target area. A7. The system of A1, wherein the formed part is doubly curved. A8. The system of A1, wherein the cold spray uses helium or nitrogen gas. A9. The system of A1, wherein removing the completed workpiece from the mold includes using a release agent to remove the completed workpiece from the mold. A10. A method of manufacturing a completed workpiece having a formed part, the method comprising: a step of cold spraying an additive onto the workpiece in progress; a step of positioning the workpiece in progress onto a mold having a concave surface; a step of superplastic forming the workpiece in progress into a completed workpiece having a formed part, wherein the formed part matches the shape defined by the concave surface; a step of removing the completed workpiece from the mold; and including Cold spraying of the additive results in an increase in the thickness of the finished workpiece in the target area, Method. A11. The unfinished workpiece includes a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel, according to the method of A10. A12. At least a part of the target area overlaps with at least a part of the formed part, according to the method of A10. A13. The increased thickness of the finished workpiece in the target area tapers at the edge of the target area, according to the method of A10. A14. The formed part is doubly curved, according to the method of A10. A15. The increased thickness provides structural reinforcement of the finished workpiece in the target area, according to the method of A10. A16. Cold spraying uses helium or nitrogen gas, according to the method of A10. A17. Removing the finished workpiece from the mold includes using a release agent to remove the finished workpiece from the mold, according to the method of A10. A18. A method of manufacturing a finished workpiece having a formed part, the method comprising: Cold spraying an additive onto a mold having a concave surface; Positioning an unfinished workpiece on the mold; Superplastic forming the unfinished workpiece and diffusion bonding the cold-sprayed additive to the unfinished workpiece, thereby converting the unfinished workpiece into a finished workpiece having a formed part, the formed part conforming to the shape defined by the concave surface; Removing the finished workpiece from the mold; and Including, Cold spraying of the additive results in an increase in the thickness of the finished workpiece in the target area, Method. A19. The unfinished workpiece comprises a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel, according to the method of A18. A20. A method according to A18, wherein at least a part of the additive is cold-sprayed into the concave surface, and at least a part of the target area overlaps with at least a part of the formed part. A21. A method according to A18, wherein the increased thickness provides structural reinforcement of the finished workpiece in the target area. A22. A method according to A18, wherein the cold spray uses helium or nitrogen gas. A23. A method according to A18, wherein the increased thickness of the finished workpiece in the target area tapers at the edge of the target area. A24. A method according to A18, wherein the formed part is doubly curved. A25. A method according to A18, wherein removing the finished workpiece from the mold includes using a release agent to remove the finished workpiece from the mold. A26. A method of manufacturing a finished workpiece having a formed part, the method comprising: positioning an unfinished workpiece on a mold having a concave surface; superplastically forming the unfinished workpiece to form a formed part on the unfinished workpiece, the formed part conforming to the shape defined by the concave surface; removing the unfinished workpiece from the mold; cold-spraying an additive onto the unfinished workpiece, thereby converting the unfinished workpiece into a finished workpiece; and wherein the cold spraying of the additive results in an increase in the thickness of the finished workpiece in the target area. A method. A27. A method according to A26, wherein the unfinished workpiece includes a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel. A28. A method according to A26, wherein at least a part of the target area overlaps with at least a part of the formed part. A29. A method according to A26, wherein the increased thickness of the finished workpiece in the target area tapers at the edge of the target area. A30. A method according to A26, wherein the formed part is doubly curved. A31. The method of A26, wherein the increased thickness provides structural reinforcement of the finished workpiece in the target area. A32. The method of A26, wherein cold spray uses helium or nitrogen gas. A33. The method of A26, wherein removing the unfinished workpiece from the mold includes removing the finished workpiece from the mold using a release agent. A34. A method of fabricating a finished workpiece having a formed portion, the method comprising: placing a cold-sprayed additive on an upper surface of a mold having a concave surface; positioning an unfinished workpiece on the mold; superplastically forming the unfinished workpiece and diffusion bonding the cold-sprayed additive to the unfinished workpiece, thereby converting the unfinished workpiece into a finished workpiece having a formed portion, the formed portion conforming to a shape defined by the concave surface; removing the finished workpiece from the mold; and wherein the cold spray of the additive results in an extended length of the finished workpiece relative to the length of the unfinished workpiece. The method. A35. The method of A34, wherein the unfinished workpiece comprises a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel. A35. The method of A34, wherein the step of placing the cold-sprayed additive on the mold includes cold spraying the additive onto the mold. A36. The method of A34, wherein the step of placing the cold-sprayed additive on the mold includes placing the cold-sprayed additive within the concave surface. A37. The method of A34, wherein the cold-sprayed additive tapers at its edges. A38. The method of A34, wherein the formed portion is doubly curved. A39. The method of A34, wherein cold spray uses helium or nitrogen gas. A40. The method of A34, which includes removing the completed workpiece from the mold, including removing the completed workpiece from the mold using a release agent. A42. A method of manufacturing a completed workpiece having a formed portion, the method comprising: receiving requirements regarding the completed part; selecting configurations regarding CSAM components and SPFDB components; configuring CSAM components and SPFDB components according to the selection; receiving an unfinished workpiece; converting the unfinished workpiece into a completed workpiece, wherein converting into a completed workpiece includes: cold spraying an additive onto the unfinished workpiece using a CSAM component; performing superplastic forming on the unfinished workpiece using a mold using an SPFDB component; and the method. A43. A method of manufacturing a sandwich structure, the method comprising: cold spraying an additive onto at least one workpiece among a plurality of workpieces used in the sandwich structure; performing superplastic forming and diffusion bonding on the plurality of workpieces to form a sandwich structure; cold spraying an additive onto the sandwich structure; and the method. A44. The method of A43, wherein the sandwich structure includes four sandwich structures. A45. The method of A43, wherein the increase in the thickness of the additive provides structural reinforcement for the sandwich structure. A46. The method of A43, wherein cold spraying uses helium or nitrogen gas.

[0065] When introducing elements of the present disclosure or embodiments thereof, the articles "a", "an", "the", and "said" are intended to mean that one or more elements are present. The terms "comprising", "including", and "having" are intended to be inclusive and mean that additional elements beyond the listed elements may exist. The term "implementation form" is intended to mean "an example of ~". The phrase "one or more of the following A, B, and C" means "at least one of A and / or at least one of B and / or at least one of C".

[0066] It will be apparent that the embodiments of the present disclosure have been described in detail and that modifications and variations are possible without departing from the scope of the embodiments of the present disclosure as defined in the appended claims. Since various changes can be made to the above structures, products, and methods without departing from the scope of the embodiments of the present disclosure, all matters included in the above description and shown in the accompanying drawings are intended to be construed as illustrative and not in a limiting sense.

Explanation of Reference Numerals

[0067] 56 dies 58 metal blanks 100 system 110 unfinished workpiece 110a unfinished workpiece 110b unfinished workpiece 110c unfinished workpiece 110d unfinished workpiece 111 facing side 112 back side 120 finished workpiece 122 formed part 124 target area 126 tapered edge 128 sharp edge 130 location 132 extended length of the finished workpiece 120 134 length of the unfinished workpiece 136 Length provided by deposit 376 150 Mold 150a Mold 150b Mold 152 Concave surface 152a Concave surface 152b Concave surface 200a Configuration of system 100 200b Configuration of system 100 200c Configuration of system 100 200d Configuration of system 100 300 CSAM component 301 CSAM material 302 Cold spray device 303 Additive 304 Nozzle 305 Particle flow 306 Gas control module 307 Gas 310 Heater 314 First line 316 Second line 318 Powder chamber 330 Robot control system 332 Robot positioning arm 370 Deposit 372 Deposit 374 Deposit 376 Deposit 400 SPFDB component 401 SPFDB material 402 SPFDB device 403 Release agent 404 Inlet line 406 Gas control module 407 Gas 408 Inlet 410 Lid 412 Molding chamber 414 Inlet line 416 Second gas line 418 Lid passage 420 Passage in molding chamber 422 Heater 501 Stage of changing an unfinished workpiece into a finished workpiece 502 Stage of changing an unfinished workpiece into a finished workpiece 503 Stage of changing an unfinished workpiece into a finished workpiece 701 Stage of changing an unfinished workpiece into a finished workpiece 702 Stage of changing an unfinished workpiece into a finished workpiece 703 Stage of changing an unfinished workpiece into a finished workpiece 901 Stage of changing an unfinished workpiece into a finished workpiece 902 Stage of changing an unfinished workpiece into a finished workpiece 903 Stage of changing an unfinished workpiece into a finished workpiece 1101 Stage of changing an unfinished workpiece into a finished workpiece 1102 Stage of changing an unfinished workpiece into a finished workpiece 1103 Stage of changing an unfinished workpiece into a finished workpiece 1400 Arrangement of multi - sheet SPFDB 1402 Sandwich structure 1404a Inner pocket 1404b Inner pocket 1404c Inner pocket 1404d Inner pocket 1410 Gas line 1412a Joint 1412b Joint 1412c Joint 1500 Sandwich structure 1501 Surface layer 1502 First core layer 1503 Second core layer 1504 Second surface layer 1510 Second gas line 1602 Pad of additive 1604 Pad of additive 1606 Pad of additive 1608 Pad of additive 1612 Pad of additive Pad of Additive 1614 Pad of Additive 1616 Pad of Additive 1618 Computing Device 1800 Processor 1819 Operating System 1820 Application Software 1821 Memory 1822 Communication Interface 1823 Input / Output Controller 1824 Output 1825 Input 1826 Device Manufacturing and Service Method 1900 Device 2000 Aircraft (Flight Module) 2001 Ground Transportation Module 2002 Modular Device 2003 Airframe 2102 Multiple Systems 2104 Interior 2106 Propulsion System 2108 Electrical System 2110 Hydraulic System 2112 Environmental System 2114

Claims

1. A system (100) for fabricating a finished workpiece (120) having a formed portion (122), the system (100) comprising: a superplastic forming diffusion bonding (SPFDB) component (400); a cold spray additive manufacturing (CSAM) component (300); and a mold (150) having a concave surface (152), wherein the system (100) is configured to: receive an unfinished workpiece (110); use the CSAM component (300) to cold spray an additive (303) onto the concave surface of the mold to form a deposit; position the unfinished workpiece (110) against the mold (150), thereby diffusion bonding the deposit to the unfinished workpiece (110), and then use the SPFDB component (400) to perform superplastic forming on the unfinished workpiece (110) using the mold (150) to convert the unfinished workpiece (110) into a finished workpiece (120) having the formed portion (122), the formed portion (122) conforming to the shape defined by the concave surface (152). A system (100) configured as such.

2. The system (100) according to claim 1, wherein the unfinished workpiece (110) comprises a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel.

3. The system (100) according to claim 1, wherein the system (100) is configured to cold spray the additive (303) to effect an increase in the thickness of the finished workpiece (120) in a target region (124).

4. The system (100) according to claim 3, wherein at least a portion of the target region (124) overlaps at least a portion of the formed portion (122).

5. The system (100) according to claim 3, wherein the increased thickness provides structural reinforcement of the finished workpiece (120) in the target region (124).

6. The system (100) according to claim 3, wherein the system (100) is configured to taper the increased thickness of the finished workpiece (120) at an edge (126) of the target region (124).

7. The system (100) according to claim 1, wherein the system (100) is configured to doubly curve the formed part (122).

8. The system (100) according to claim 1, wherein the cold spray additive manufacturing component (300) uses helium or nitrogen gas.

9. A method of fabricating a finished workpiece (120) having a formed part (122), the method comprising: Cold spraying an additive (303) onto a concave surface of a mold to form a deposit; Positioning an unfinished workpiece (110) on the mold (150); Placing the unfinished workpiece (110) relative to the mold (150) and diffusion bonding the deposit to the unfinished workpiece (110) to superplastically form the unfinished workpiece (110) into the finished workpiece (120) having the formed part (122), wherein the formed part (122) conforms to the shape defined by the concave surface (152); Removing the finished workpiece (120) from the mold (150); and wherein the cold spraying of the additive (303) results in an increase in the thickness of the finished workpiece (120) in a target region (124). Method.

10. The method according to claim 9, wherein the unfinished workpiece (110) comprises a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel.

Images