Apparatus, method, and product for cold spray additive manufacturing of multi-bend strengthening components

Abstract

To provide a mold for manufacturing a complex multiple curvature part (CMCP) by cold spray onto the mold based on a cold spray additive manufacturing (CSAM), and a method for implementing the CSAM.SOLUTION: The mold includes a first part 102 and a second part 104. The first part and the second part are configured to be adjacent and engaged to each other contiguously so that a gap 106 is formed along a long direction between them. An outer face 108 of the first part engaged to the second part becomes a complex form 110. The mold further includes a reinforcement member 112 positioned within the gap. The first part, the second part and the reinforcement member are configured to be cold sprayed so as to form an integrated component. The reinforcement member is unified with the integrated component.SELECTED DRAWING: Figure 1

Description

Background Art

[0001] In various manufacturing fields, the manufacture of complex (e.g., multi-curved reinforced) parts (also referred to herein as "complex multi-curvature parts" (CMCPs)) is a complex and time-consuming process. Such parts include at least two surfaces with different radii of curvature and parts that reinforce those surfaces. Conventional manufacturing involves multiple individual steps and often requires parts and equipment that must be obtained from various suppliers. Such logistical challenges increase costs and manufacturing time and raise the risk that such problems, singly or in combination, will make manufacturing prohibitively expensive in certain cases. Generally, conventional manufacturing of CMCPs begins by deforming a thin layer of material to reduce the thickness of a particular region of the CMCP being manufactured while achieving the desired shape and dimensions. However, in conventional manufacturing, it is difficult and in some cases impossible to control the thickness and shape of the CMCP being manufactured, especially when it is desired for the surface thickness to vary. After this deformation and shaping stage, a reinforcing material (also referred to herein as a "reinforcement") is added to maintain rigidity and prevent fluttering and the like.

[0002] In many aerospace applications that utilize CMCPs, each CMCP is attached to at least one reinforcement, which serves the dual purpose of (1) maintaining the shape of the CMCP surface under load and (2) transmitting the load applied to the CMCP surface to the support structure below the CMCP. Such conventional reinforcements are often rivets. The use of conventional rivet reinforcements or equivalents increases the cost and complexity of part manufacturing and also extends the manufacturing time.

[0003] The conventional manufacturing of CMCP requires the integration of multiple components and processes. Typically, the surface part is formed by superplastic forming, hydroforming, sequential forming, or similar methods. In particular, diffusion bonding in superplastic forming is a complex and expensive technique that can form hard parts with multiple curved portions, but it cannot fully control the surface thickness of the manufactured CMCP, and it is necessary to add a reinforcing material in a subsequent step, increasing the processing time and also increasing the manufacturing tolerance due to the tendency of component inconsistency to increase. In conventional manufacturing, the reinforcing material is formed in an independent step, for example, in a step separate from the cold spray additive manufacturing (cold spray additive manufacturing) process. Furthermore, in conventional manufacturing, the poor tolerance between components results in manufacturing inconsistencies and requires shims and other post-manufacturing adjustments to compensate for the poor tolerance.

[0004] Therefore, the conventional manufacturing of CMCP is expensive and time-consuming, requires a large number of components and labor-intensive and complex manufacturing steps, often cannot avoid the poor tolerance that requires rework and other corrections (such as shims) after manufacturing is completed, requires riveting and other attachment methods with complex load transfer behavior, reduces the maximum load of the finished product, increases the total weight of the finished product, and cannot deliver a finished product with a deliberately varying surface thickness. Summary of the Invention Means for Solving the Problems

[0005] One embodiment provides a mold for cold spray additive manufacturing (CSAM). The mold includes a first part and a second part. The first part and the second part are configured to engage adjacent to each other such that a gap is formed along the longitudinal direction therebetween. The outer surface of the first part engaged with the second part has a complex shape. The mold further includes a reinforcing member positioned within the gap. The first part, the second part, and the reinforcing member are configured to be cold sprayed to form an integrated component. The reinforcing member becomes integral with the integrated component.

[0006] Another embodiment provides a method for performing CSAM. The method includes configuring a mold to have a first part and a second part. A gap is formed along the longitudinal direction between the first part and the second part. The outer surface of the first part engages with the second part to form a complex shape. The method further includes disposing a reinforcing member within the gap, performing a first cold spray on (i) one of the first part and the second part and (ii) the reinforcing member, and performing a second cold spray on the other part to form an integrated component. The reinforcing member becomes integral with the integrated component.

[0007] Yet another embodiment provides an integrated component manufactured by the CSAM method. The CSAM method includes the step of configuring a mold to have a first part and a second part. A gap is formed along the longitudinal direction between the first part and the second part. The outer surface of the first part engages with the second part to form a complex shape. The CSAM method further includes disposing a reinforcing member within the gap, performing a first cold spray on (i) one of the first part and the second part and (ii) the reinforcing member, and performing a second cold spray on the other part to form an integrated component. The reinforcing member is integral with the integrated component.

[0008] This summary selectively introduces concepts in a simplified form and will be further explained in the following detailed description. The above summary and the following detailed description of specific embodiments are better understood when read in conjunction with the accompanying drawings. This summary does not identify the key features or essential features of the claimed subject matter, nor is it used to determine the scope of the claimed subject matter.

[0009] The above and other features, aspects, and advantages of the present disclosure will be better understood by reading the following detailed description in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0010]

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Best Mode for Carrying Out the Invention

[0011] Corresponding reference numerals in the embodiments indicate corresponding parts throughout the drawings.

[0012] Cold spray additive manufacturing (also referred to as "cold spray" or "CSAM" in this application) is a material deposition (laminated manufacturing) method of forming a coating or a self-supporting structure using a powder of a metal or a metal-ceramic mixture that floats in a gas propelled at supersonic speed (also referred to as "particles" in this application). Specifically, in this application, cold spraying is defined as spraying the substance at a temperature below the melting point of the substance to be sprayed (sprayed). CSAM is a solid-state process, that is, neither the powder nor the substrate to which the powder is applied melts during the process. Therefore, the use of CSAM provides a material deposition method that does not cause thermally induced changes (e.g., deformation, crystallization, defects, other types of damage) to the substrate or the powder. By directly applying the gas carrying the powder onto the substrate, cold spray generates a steady shock wave and also causes a lateral flow of the gas along the surface of the portion receiving CSAM.

[0013] High-pressure cold spray and low-pressure cold spray are emerging technologies with increasingly diverse applications in the repair of various types of structures and the manufacturing of components. In some embodiments, high-pressure or low-pressure cold spray can be used to construct metallic structures (e.g., parts of airplanes and helicopters). A more detailed examination of CSAM devices and processes is provided in the discussion of FIG. 8 of this application.

[0014] Referring to the drawings, embodiments of the present disclosure include apparatuses, methods, and products for the CSAM-based manufacturing of complex (e.g., multi-curved reinforcement) parts (also referred to herein as "complex multi-curved parts" or "CMCPs"). The present disclosure provides apparatuses, methods, and products for streamlining, accelerating, and reducing the cost of cold spray additive manufacturing of CMCPs. The present disclosure requires few individual steps and does not require obtaining parts and equipment from various suppliers. Removing such logistical challenges reduces costs, shortens manufacturing times, and reduces the risk that such problems, alone or in combination, will make the manufacturing of CMCPs by CSAM prohibitively expensive in certain cases.

[0015] The manufacturing of CMCPs based on CSAM is achieved by using a cold spray-based method in combination with the molds of the present disclosure. Cold spray enables the construction of each CMCP directly on the mold with precise specifications, so there is no need to attempt to deform a pre-made thin layer of material to reduce the thickness of a specific area of the CMCP being manufactured while achieving the desired shape. Thus, the present disclosure completely avoids the difficulties associated with conventional processes with respect to controlling the thickness of various surface portions while achieving the desired shape and dimensions of the finished CMCP (including CMCPs with varying surface thicknesses).

[0016] The elements of the present disclosure in various embodiments function in an unconventional manner to provide an apparatus, a method, and a product for the manufacture of CMCPs based on CSAM by utilizing a reinforcement integrated with the finished CMCP. Embodiments of the present disclosure include adding a reinforcement during the CSAM process such that the reinforcement is placed in position and integrated with each CMCP as soon as CSAM-based manufacturing is completed. Such reinforcements maintain rigidity, prevent fluttering (unstable vibrations that can lead to the failure of the structure), and provide other similar advantages to the CMCPs being manufactured. Thus, CSAM is ideal for manufacturing integrally reinforced CMCPs having a surface with complex curvatures and a structure with complex geometries.

[0017] The present disclosure enables the fabrication of rigid CMCPs having multiple curvatures where the fabricator has complete control over the surface thickness of the CMCP. Since the integrated reinforcement is added during the fabrication of the CMCP, there is no need to add the reinforcement later. This, compared to the manufacture of conventional CMCPs, eliminates the need to align the un-reinforced CMCP with the reinforcement at a later stage, reducing processing time and preventing problems with poor tolerances due to its integral structure. Preventing such manufacturing misalignments, i.e., the associated poor tolerances, further eliminates the need for shims and other post-manufacturing adjustments.

[0018] Accordingly, the embodiments of the present disclosure are superior to the implementation of the manufacture of typical CMCPs that rely on adding non-integrated reinforcing materials at a later stage of the manufacturing process rather than using an integrated reinforcing material for the finished CMCP. The performance of the apparatus, method, and product embodiments for manufacturing CMCPs based on the CSAM of the present disclosure is substantially equal to, and in some cases superior to, the apparatus, method, and product for manufacturing CMCPs based on the conventional CSAM, particularly due to the advantages of the integrated reinforcing material introduced during the manufacture of the CMCP as described above. The present disclosure reduces costs and manufacturing time, requires a smaller number of parts compared to conventional methods, and has fewer labor-intensive and complex manufacturing steps. The CMCP based on the CSAM of the present disclosure has a reinforcing material directly integrated during CSAM-based manufacture and exhibits excellent tolerances that do not require rework or other modifications after manufacture. Riveting and other attachment methods with complex load transfer behavior are unnecessary. In some embodiments, simplifying the load transfer by simplifying the load path (e.g., the direction in which each successive load on the load-bearing structure passes through each connecting member of the load-bearing structure) increases the maximum load of the finished CMCP and reduces the total weight of the finished CMCP.

[0019] The present disclosure can readily deliver a CMCP finished to have a plurality of surface portions with intentionally varying thicknesses, which can be precisely controlled by the manufacturer of the CMCP. The cold spray method enables the realization of an inclined function CMCP with a varying surface thickness manufactured as described in the present disclosure, even when the reinforcing material and the remaining portion of the CMCP have compatible but dissimilar materials. Accordingly, the present disclosure is mechanically more robust and cost-effectively implemented, and at the same time is more effective than the apparatus, method, and product for manufacturing conventional CMCPs.

[0020] Referring back to FIGS. 1A - 1G, FIGS. 1A - 1G are perspective views of a mold 100 for cold spray additive manufacturing used to form an integrated component 150 according to an embodiment. The mold 100 includes a first part 102 and a second part 104. The first part 102 and the second part 104 are configured to engage adjacent to each other. A gap 106 is formed therebetween along the longitudinal direction. In some embodiments, the gap 106 is formed by a cutout 114 in one of the first part 102 and the second part 104. In such some embodiments, the cutout 114 extends only along a sub - section 116 of one side 118 of the first part 102 or the second part 104. Each cutout 114 forms a ridge 120 that extends longitudinally along the sub - section 116.

[0021] The outer surface 108 of the first part 102 engages with the second part 104. The outer surface 108 of the first part 102 engaged with the second part 104 has a complex shape 110. In some embodiments, the complex shape 110 includes a plurality of different curved portions 122. For example, the plurality of curved surfaces that the complex shape 110 may include may have the same or different radii of curvature and may curve in the same or different directions.

[0022] The mold 100 further includes a reinforcement member 112 positioned within the gap 106. In some embodiments, the reinforcement member 112 is a flat reinforcement (e.g., a reinforcement member having a flat surface that extends in a plane). However, it should be understood that in some embodiments, the reinforcement is curved.

[0023] The first part 102, the second part 104, and the reinforcement member 112 are configured to be cold sprayed to form the integrated component 150. The integrated component 150 includes the reinforcement member 112 as being integral therewith. By the end of the cold spray process, the integrated component 150 assumes at least approximately its net shape (e.g., becomes very close to the target shape, reducing the need for final machining). In such an embodiment, a final machining process is performed according to the intended specifications and tolerances of the integrated component 150 to bring the integrated component 150 to the desired exact shape. In some embodiments, a segment 124 of the reinforcement member 112 extends from the outer surface 154 of the integrated component 150. After the cold spray is completed, the segment 124 is machined to be flush with the outer surface 154 of the integrated component 150. Such an embodiment enables the standard shapes and sizes of any reinforcement member 112 to be routinely used in combination with any mold 100 having any combination of shapes and sizes without the need to first modify the reinforcement member 112 to match the exact shape and size of the mold 100 prior to cold spraying. Since the excess non-flat portions of the segment 124 are removed after the cold spray is completed, the CSAM of the present disclosure is mechanically simple, fast, inexpensive, and less error-prone. By curving the first part 102 and the second part 104 of the mold 100 along the contact region of the reinforcement member 112 (bringing them into contact), the reinforcement member 112 can be made to have out-of-plane curvature.

[0024] A mold 100 of some embodiments further includes a support device 126 configured to support the reinforcement member 112 within the gap 106. In such some embodiments, the support device 126 comprises at least one of a fastener, a vacuum suction portion, and a magnetic coupling portion. A mold 100 of other embodiments further includes a support member 128 positioned to support the reinforcement member 112 in the gap 106.

[0025] In one embodiment, the integrated component 150 formed by cold spray includes at least one surface portion 152 with a varying thickness. In some embodiments, having a varying thickness means that the at least one surface portion 152 can be divided into a plurality of sub-units each defined as having a specific thickness. In still other embodiments, having a varying thickness means that each of the at least one surface portion 152 has a uniform thickness defined independently of the thickness of the other at least one surface portion 152. In still other embodiments, having a varying thickness means that the at least one surface portion 152 exhibits a combination of the above definitions of having a varying thickness.

[0026] In one embodiment, the mold 100 can be used in combination with a CSAM process to form complex integrated components 150 (the CSAM process using the mold 100 is the "mold process"). As shown in FIG. 1A, the first part 102 of the mold 100 is a complex three-dimensional mold. Depending on the intended application, the mold 100 can be manufactured from a variety of materials compatible with CSAM. In some embodiments, the material sprayed onto the mold 100 to manufacture the integrated component 150 is the same type of material as the mold 100. Suitable CSAM-compatible materials for constructing the mold 100 include, but are not limited to, aluminum, inconel, steel, zinc, brass, monel, stainless steel, zirconium, bronze, nickel, tantalum, copper, niobium, tin, refractory metals compatible with CSAM, chromium carbide nickel chromium (CrC-NiCr), silver, titanium.

[0027] Before use, both the first part 102 and the second part 104 of the mold 100 must be prepared such that the substance cold-sprayed onto the mold 100 can be non-destructively separated from the mold 100. In some embodiments, the first part 102 and the second part 104 of the mold 100 are surface-treated to facilitate non-destructive separation. In such some embodiments, the surface treatment comprises applying a coating of a surface treatment (e.g., a liquid film) to the first part 102 and the second part 104. In some embodiments, the liquid film is a lanolin-based fluid film that leaves a wet and non-drying corrosion-resistant layer on the surface to which the liquid film is applied. The surface treatment part is removable from the mold 100 after use (e.g., for cleaning or maintenance inspection of the mold 100). Various types of surface treatments are applicable to the same mold 100. The type of surface treatment selected depends on the requirements in a specific application.

[0028] At least one of the first part 102 and the second part 104 of the mold 100 has a recess (e.g., a cutout 114). The recess is configured to support a reinforcing member (e.g., a strengthening member 112) in its vicinity. The reinforcing member is made of the same material as the mold 100 or a material known to be mechanically compatible with the material of the mold 100.

[0029] As shown in FIG. 1B, the second part 104 of the mold is shaped such that at least one side of the second part 104 has the same shape and dimensions as the side of the first part 102 having a recess. FIG. 1B shows the first part 102 engaging adjacent to the second part 104 so as to have an overall complex shape of the mold 100. In some embodiments, both the first part 102 and the second part 104 have the same recesses that are mirror images. Such embodiments allow the use of a thicker, i.e., stronger, reinforcing member. When the first part 102 engages adjacent to the second part 104 while the reinforcing member is supported in the vicinity of either the first part 102 or the second part 104, the mold 100 firmly confines the reinforcing member and holds the reinforcing member in place with respect to the first part 102 and the second part 104.

[0030] As shown in FIG. 1C, a reinforcing member is cut to fit the contour of at least one of the recesses of the first part 102 and the second part 104 of the mold 100 to optimize the support provided to the reinforcing member by the recess. In some embodiments, the cut reinforcing member functions as an internal plate between the first part 102 and the second part 104. The reinforcing member is trimmed to follow the curvature of either the first part 102 or the second part 104 of the mold 100. In some embodiments, the trimmed reinforcing member projects at least partially from either the first part 102 or the second part 104 of the mold 100.

[0031] As shown in FIG. 1D, after cutting the reinforcing member to fit the contour of the recess of either the first part 102 or the second part 104 of the mold 100 to optimize the support provided to the reinforcing member by the recess, the first part 102 and the second part 104 engage adjacent to each other such that the mold 100 is proximate to both sides of the reinforcing member and holds the reinforcing member in place with respect to the first part 102 and the second part 104. When the reinforcing member is installed in this way, the mold 100 is ready for the CSAM manufacturing process.

[0032] As shown in FIG. 1E, the first CSAM coating comprises (i) cold spraying a first part of either the first part 102 or the second part 104 and (ii) the reinforcing member. In some embodiments, a robotic arm (e.g., as described below with respect to FIG. 8) is used to perform the CSAM process. Which of the first part 102 and the second part 104 to cold spray first depends on the specific application and does not affect the overall result unless otherwise specified. During the CSAM process, a material is cold sprayed onto (i) a part of either the first part 102 or the second part 104 and (ii) the reinforcing member as required by the specific application. After such a CSAM process is completed, (i) either the first part 102 or the second part 104 and (ii) the reinforcing member are integrated and form a partial integrated component.

[0033] As shown in FIG. 1F, the second CSAM coating comprises performing a second cold spray of a material with various thicknesses over a partial integrated component and over the part of the first part 102 or the second part 104 where cold spray has not been performed. The first part 102, the second part 104, and the reinforcing material are close to each other as described above and have each been coated by CSAM, so an integrated component 150 is formed close to the mold 100. The reinforcing material is integral with the entire integrated component 150, and the reinforcing material cannot be nondestructively removed from the integrated component 150. In some embodiments, the surface portion of the integrated component 150 has a varying thickness as defined in the present application.

[0034] In some embodiments, by using the method described above to perform cold spray on the first part 102 of the mold 100 and then performing cold spray on the second part 104 of the mold 100, excellent bonding (connection) between the mold 100, the reinforcing material, and the cold spray feedstock in use is easily ensured. This ensures sufficient (e.g., permanent or semi-permanent without intentional disassembly or accidental destruction) joints or seals between the reinforcing material and the integrated component 150 incorporating the reinforcing material.

[0035] In some embodiments, continuous CSAM is used across both the first part 102 and the second part 104 of the mold 100. This is in contrast to performing cold spray first on the first part 102 and then on the second part 104, or vice versa. In some embodiments where continuous CSAM is used depending on the application (e.g., the shape of the mold 100), the direction in which the robot moves while performing CSAM while depositing the cold spray material determines the quality of the structure of the integrated component 150. In such embodiments, the user or a semi-automated or automated CSAM device must select the direction that provides optimal results. In some of such embodiments, left-right movement across the mold 100 provides optimal results.

[0036] Figure 1G shows the integrated component 150 when all CSAM processes are completed. As shown in Figure 1G, the integrated component 150 has been removed from the mold 100 (e.g., by being lifted by a user or a robotic arm). As described above, the integrated component 150 incorporates a reinforcing material and it has become impossible to nondestructively remove the reinforcing material from the integrated component 150. After removal from the mold 100, the residue of the surface treatment used to prevent the mold 100 from sticking to the integrated component 150 can be removed from the integrated component 150.

[0037] In some embodiments, a segment 124 of the reinforcing material extends from the outer surface 154 of the integrated component 150. To complete the manufacture of the integrated component 150, the segment 124 is machined to be flush with the outer surface 154 of the integrated component 150. In some embodiments, once machining is complete and the segment 124 is flush with the outer surface 154, the segment becomes visually indistinguishable from the rest of the integrated component 150. In some embodiments, the proportion (amount) of the segment 124 that is machined is limited by the need to ensure that such machining does not impair the usefulness of the reinforcing material.

[0038] In some alternative embodiments of the above-described molding process, the mold as a whole does not have a curved portion, and neither the first part 102 nor the second part 104, which are its components, has a curved portion. In such embodiments, the non-curved integrated component 150 is formed as described above, and a curved portion is added as part of the final process including machining and other processes (not limited thereto).

[0039] In other alternative embodiments of the molding process, the reinforcing material is replaced by an alternative mechanism. Such alternative mechanisms include, but are not limited to, at least one of a bracket, a shelf, a clamp, and other similar mechanical parts.

[0040] FIG. 2 is a flow diagram 200 showing the use of a male metal mold for cold spray additive manufacturing used to form an integrated component according to an embodiment. In some embodiments, the male metal mold is mold 100 of FIGS. 1A-1F. In some embodiments, the integrated component is integrated component 150 of FIG. 1G. In step 202, the mold is separated into a first part (e.g., first part 102 of FIGS. 1A-1F) and a second part (e.g., second part 104 of FIGS. 1A-1F). In step 204, a reinforcing material (e.g., reinforcing member 112 of FIGS. 1A-1F) is prepared. In step 206, the first part and the second part are configured to engage adjacent to each other such that a longitudinal gap (e.g., gap 106 of FIGS. 1A-1F) is formed therebetween. The outer surface of the first part (e.g., outer surface 108 of FIGS. 1A-1F) engages with the second part to form a complex shape (e.g., complex shape 110 of FIGS. 1A-1G). The reinforcing material is positioned within the gap. Upon completion of step 206, the mold is surface treated as described herein and is ready for the CSAM process. In step 208, a cold spray process is performed to form the integrated component as described herein. In step 210, the integrated component is removed from the mold as described herein. Depending on the configuration of the mold, in some embodiments, a segment of the reinforcing material (e.g., segment 124 of FIGS. 1A-1G) extends from the outer surface (e.g., outer surface 154 of FIG. 1G). In such some embodiments, the segment is machined as described herein to be flush with the outer surface of the integrated component, although this step is not shown in FIG. 2.

[0041] In the specific embodiment shown in FIG. 2, the CSAM process is performed with respect to the front surface of the mold, and the segment of the reinforcing material extends from the back surface of the integrated component. In this embodiment, the mold is removed from the back surface of the integrated component, and prior to machining, the segment of the reinforcing material extends from the outer surface of the back surface of the integrated component.

[0042] Figure 3 is a flowchart 300 showing the use of a male detachable mold for cold spray additive manufacturing used to form an integrated component according to an embodiment. In some embodiments, the male detachable mold is the mold 100 of FIGS. 1A-1F. In some embodiments, the integrated component is the integrated component 150 of FIG. 1G. Prior to use, the mold is surface treated as described herein and is ready for the CSAM process. Reinforcing material (e.g., the reinforcing member 112 of FIGS. 1A-1F) is prepared in step 302. In step 304, a ceramic green body or equivalent material is filled into the mold. The ceramic green body is an un-fired or un-sintered, weakly bonded clay material conventionally used in the form of a bonded powder or plate. In step 306, the reinforcing material is inserted into the mold. In some embodiments, step 306 is performed before step 304. The outer surface of the mold containing the reinforcing material and the ceramic green body (e.g., the outer surface 108 of FIGS. 1A-1G) forms a complex shape (e.g., the complex shape 110 of FIGS. 1A-1G). In step 306, the outer surface of the mold undergoes the CSAM process as described herein to form an integrated component. At the completion of step 306, the mold is inside the integrated component.

[0043] In step 310, the mold is damaged, dissolved, or broken so that only the integrated component integrally formed with the reinforcing material remains. This breaking or dissolving is achieved through heat treatment, agitation, application of controlled vibration, or any other means suitable for breaking the mold without impairing or affecting the structural integrity of the integrated component or the reinforcing material or the ceramic green body (or equivalent) therein. Depending on the configuration of the mold, in some embodiments, segments of the reinforcing material (e.g., the segment 124 of FIGS. 1A-1G) extend from the outer surface of the integrated component (e.g., the outer surface 154 of FIG. 1G). In such some embodiments, the segments are machined flush with the outer surface of the integrated component as described herein, but this step is not shown in FIG. 3.

[0044] FIG. 4 is a flowchart showing a method 400 for cold spray additive manufacturing using a mold according to an embodiment (e.g., mold 100 of FIGS. 1A-1F). In some embodiments, the process shown in FIG. 4 is at least partially performed by a first part having an outer surface, a second part, a gap, and a mold having a reinforcement member (e.g., a first part 102 having an outer surface 108 of FIGS. 1A-1F, a second part 104, a gap 106, and a mold 100 having a reinforcement member 112). In some embodiments, method 400 forms an integrated component such as integrated component 150 of FIG. 1G.

[0045] In step 402 of method 400, a mold is configured to have a first part and a second part, with a gap formed longitudinally between the first part and the second part. In some embodiments, the mold comprises an outer surface having a plurality of different curvatures. By the end of step 402, the outer surface of the first part engages the second surface and assumes a complex shape. In step 404, a reinforcement member is disposed within the gap. In some embodiments, the reinforcement member is a flat reinforcement.

[0046] In step 406, a first cold spray is performed on (i) one of the first part and the second part and (ii) the reinforcement member. In step 408, a second cold spray is performed on the other part to form an integrated component. The reinforcement member becomes integral with the integrated component. In some embodiments, the first cold spray and the second cold spray create at least one surface portion of varying thickness in the integrated component as defined in the present disclosure.

[0047] Thereafter, the process is completed. The steps shown in FIG. 4 are at least partially performed by a mold having a first part with an outer surface, a second part, a gap, and a reinforcement member, but aspects of the present disclosure contemplate the performance of the steps in other manners. In some embodiments, a cloud service performs one or more of the steps (e.g., performs the first cold spray and the second cold spray).

[0048] FIG. 5 is a flowchart showing a method 500 of performing cold spray additive manufacturing using a mold according to an embodiment and further performing machining after cold spray. In some embodiments, the process shown in FIG. 5 is at least partially performed by a mold having a first part with an outer surface, a second part, a gap, and a reinforcing member (e.g., the mold 100 having the first part 102 with the outer surface 108 in FIGS. 1A - 1F, the second part 104, the gap 106, and the reinforcing member 112). In some embodiments, the method 500 forms an integrated component such as the integrated component 150 in FIG. 1G.

[0049] Steps 502, 504, 506, 508 are the same as steps 402, 404, 406, 408 of the method 400 shown in FIG. 4, and thus will not be repeatedly described. In some embodiments, a segment of the reinforcing member (the segment 124 in FIGS. 1A - 1G) extends from the outer surface of the integrated component. In such embodiments, the method 500, in step 510, machines the segment of the reinforcing member extending from the outer surface of the integrated component to be flush with the outer surface of the integrated component.

[0050] Such embodiments enable the standard use of any reinforcing member having a standard shape and size in combination with any mold having any combination of shapes and sizes, without the need to first modify the reinforcing member to fit the exact shape and size of the mold before cold spray. Since the excess non - flat portions of the segments are removed after cold spray is completed, the CSAM of the present disclosure is mechanically simple, fast, inexpensive, and less error - prone.

[0051] Thereafter, the process is completed. The steps shown in FIG. 5 are at least partially performed by a mold having a first part with an outer surface, a second part, a gap, and a reinforcing member, but aspects of the present disclosure also contemplate the implementation of the steps in other things. In some embodiments, a cloud service performs one or more steps (e.g., performs the first cold spray and the second cold spray).

[0052] FIG. 6 is a flowchart showing a method 600 for cold spray additive manufacturing using a mold and a support device according to an embodiment. In some embodiments, the process shown in FIG. 6 is at least partially performed by a mold having a first part with an outer surface, a second part, a gap, and a reinforcement member (e.g., the mold 100 having the first part 102 with the outer surface 108 in FIGS. 1A-1F, the second part 104, the gap 106, and the reinforcement member 112). In some embodiments, method 600 forms an integrated component such as the integrated component 150 in FIG. 1G.

[0053] Steps 602 and 604 are the same as steps 402 and 404 of the method 400 shown in FIG. 4, and thus will not be described repeatedly. In step 606, a support device (e.g., the support device 126 in FIGS. 1A-1F) is used to support the reinforcement member within the gap. In some embodiments, the support device is the support device 126 described in this application. In some embodiments, the support device comprises at least one of a fastener, a vacuum suction portion, and a magnetic coupling portion. Steps 608 and 610 are the same as steps 406 and 408 of the method 400 shown in FIG. 4, and thus will not be described repeatedly.

[0054] Thereafter, the process is completed. The steps shown in FIG. 6 are at least partially performed by a mold having a first part with an outer surface, a second part, a gap, and a reinforcement member, but aspects of the present disclosure contemplate the implementation of the steps with other means. In some embodiments, a cloud service performs one or more steps (e.g., performing a first cold spray and a second cold spray).

[0055] FIG. 7 is a flowchart showing a method 700 for cold spray additive manufacturing using a mold and a support member according to an embodiment. In some embodiments, the process shown in FIG. 7 is at least partially performed by a mold having a first part with an outer surface, a second part, a gap, and a reinforcement member (e.g., the mold 100 having the first part 102 with the outer surface 108 in FIGS. 1A - 1F, the second part 104, the gap 106, and the reinforcement member 112). In some embodiments, the method 700 forms an integrated component such as the integrated component 150 in FIG. 1G.

[0056] Steps 702 and 704 are the same as steps 402 and 404 of the method 400 shown in FIG. 4, and thus will not be described repeatedly. In step 706, a support member (e.g., the support member 128 in FIGS. 1A - 1F) is arranged to support the reinforcement member within the gap. In some embodiments, the support member is the support member 128 described in the present application. In some embodiments, the support member comprises at least one of a fastener, a vacuum suction portion, and a magnetic coupling portion. Steps 708 and 710 are the same as steps 406 and 408 of the method 400 shown in FIG. 4, and thus will not be described repeatedly.

[0057] Thereafter, the process is completed. The steps shown in FIG. 7 are at least partially performed by a mold having a first part with an outer surface, a second part, a gap, and a reinforcement member, but aspects of the present disclosure also contemplate performing the steps with other means. In some embodiments, a cloud service performs one or more steps (e.g., performing a first cold spray and a second cold spray).

[0058] In one embodiment, an integrated component (e.g., integrated component 150 in FIG. 1G) is an integrated component manufactured by the following process. The process comprises configuring a mold to have a first part and a second part (e.g., step 402 in FIG. 4). By the completion of step 402, a gap is formed longitudinally between the first part and the second part, and the outer surface of the first part engages with the second part to form a complex shape. The process further comprises placing a reinforcing member in the gap (e.g., step 404 in FIG. 4), performing a first cold spray on (i) one of the first part and the second part and (ii) the reinforcing member (e.g., step 406 in FIG. 4), and performing a second cold spray on the other part to form the integrated component (e.g., step 408). The reinforcing member is integral with the integrated component. In some embodiments, the first cold spray and the second cold spray result in at least one surface portion of the integrated component having a varying thickness.

[0059] The operating environment shown in FIG. 8 is a block diagram of an embodiment of a system 800 for performing cold spray additive manufacturing using a mold according to an embodiment. The system 800 includes a robot control system 802 configured to control a cold spray device 804. In some embodiments, the robot control system further includes a robot positioning arm 816 (e.g., a robot-controlled mechanical arm). In some embodiments, the robot control system 802 is a manual or at least partially automated device. In some embodiments, the robot control system can be controlled using a computing device such as the computing device 1100 of FIG. 11 of the present application. In some embodiments, the robot positioning arm 816 is at least a five-axis positioning system, including two axes for positioning within the plane of the part being repaired, one axis for the standoff distance, and two additional axes for positioning as needed. Alternatively, the robot positioning arm 816 is at least a two-axis positioning system for XY positioning within the plane of the part being repaired and a rotation system for maintaining parallelism and standoff distance from the substrate of the part being repaired. In some embodiments, the robot positioning arm 816 is an ADEPT® Viper robot manufactured by Omron Adept Technologies, Inc.

[0060] The cold spray device 804 of the system 800 further includes a supersonic nozzle 835 and is configured to perform cold spray additive manufacturing of the component 806. In some embodiments, the cold spray device 804 is further configured to cold spray the powder 830 onto the substrate 851 of the component 806. In such embodiments, the cold spray device 804 further includes a source 818 of gas 812 connected to the gas control module 820. The gas control module 820 controls the flow of gas 812 through the first line 815 connected to the supersonic nozzle 835 and the flow of gas 812 through the second line 820 connected to the powder chamber 831 and the supersonic nozzle 835. The cold spray device 804 further includes a heater 825 that heats the gas 812 to the required temperature before the gas 812 enters the supersonic nozzle 835. In some embodiments, the substrate 851 is also heated to further promote mechanical bonding (joining).

[0061] During operation, the gas 812 flows through the first line 815 and the second line 820, and the powder 830 located in the powder chamber 831 is sprayed as a particle stream 430 from the supersonic nozzle 835 as a supersonic gas jet. The particle stream 840 is sprayed at a temperature below the melting point of the powder 830 and travels supersonically from the supersonic nozzle 835. In some embodiments, the particle stream 840 travels at several times the speed of sound (the exact speed of sound at a given time varies depending on local conditions). In some embodiments, the particle stream 840 travels at at least twice to four times the speed of sound. The particle stream deposits on the substrate 851 of the component 806, and upon impact with the substrate 851, the particles of the particle stream 840 undergo plastic deformation due to the supersonic speed of the particle stream 840 and bond to each other using mechanical energy and also bond to the substrate 851 of the component 806. The heater 825 accelerates the speed of the particle stream 840, but the heat from the heated gas 812 is not transferred to the bonding of the particles of the particle stream 840. Thus, heat does not cause deformation, warping, stress, or other adverse effects on bonding. In some embodiments, when the cold spray process is completed, the substrate 851 is further processed, for example, polished to produce or restore a smooth finish.

[0062] Additional Examples Some embodiments of the present disclosure provide a CSAM process for forming an integrated component by incorporating a reinforcing material or strengthening member within the integrated component to provide at least one complex bend. In some embodiments, a computer-controlled robotic arm holds a cold spray device and uses a mathematical model to determine the number of passes necessary to form the integrated component. As a supersonic nozzle repeatedly moves over a mold, cold spray material is deposited in layers. The number of passes and the pass speed determine the thickness of the integrated component.

[0063] In some embodiments, at least one strengthening member or reinforcing material is inserted into the mold. When the robotic arm sprays onto the at least one strengthening member or reinforcing material, the at least one strengthening member or reinforcing material is integrated within the integrated component. When the CSAM process is complete, the integrated component is removed from the mold, and an integrated component of substantially net shape is formed. The at least one strengthening component or reinforcing material is integrated within the integrated component by the deposited cold spray material. Such embodiments can form multiple integrated components each having at least one complex radius of curvature. Such integrated components include, but are not limited to, the cones of airplane tails, the cones of missile noses, and fins.

[0064] Embodiments of the present disclosure provide an apparatus, method, and product for CSAM of CMCP. Some embodiments of CSAM of CMCP of the present disclosure include a support device (e.g., support device 126) configured to support a strengthening member (e.g., strengthening member 112) within a gap (e.g., gap 106). The present disclosure functions at the time of manufacture of CMCP for forming an integrated component having multiple radii of curvature resulting in a complex shape and having a strengthening member or reinforcing material integrated therewith. The present disclosure can also control the surface thickness at multiple different locations of the manufactured CMCP such that the surface thickness varies across the CMCP. The present disclosure further adds a reinforcing material to the CMCP as needed without unnecessarily increasing the weight of the CMCP.

[0065] By using a mold with a reinforcement during the manufacture of a CMCP based on CSAM, the manufacture becomes more flexible compared to conventional methods, and a CMCP with superior mechanical properties is produced. Some conventional methods (the "conventional spray method") spray a reinforcement directly onto a component to form a CMCP. In some of these conventional spray methods, the amount of reinforcement is limited, for example, there is no reinforcing member that provides the mechanical advantages of a reinforcing material that functions in combination with a mold. Some such conventional spray methods, when used with a robotic arm type CSAM device, also require additional arms (for example, one arm for spraying cold spray raw materials and another arm for spraying the reinforcement), making the manufacture of the CMCP mechanically complex, expensive, and error-prone. Some conventional cold spray methods require multiple spray passes to form a reinforcement, and the finished CMCP has a worse surface condition and requires more machining for correction compared to the integrated components of the present disclosure. In particular, spraying a reinforcement causes an accumulation of excess reinforcement, which must be removed by machining before the CMCP meets the specifications and is ready for actual use. This additional machining inevitably tends to impair the quality and effectiveness of the reinforcement.

[0066] In the present disclosure, there is no need to spray a reinforcement. Thus, the present disclosure is less wasteful, and the CMCPs manufactured by the present disclosure require less machining to meet the specifications and be ready for actual use. Thus, the molds, methods, and products of the present disclosure are mechanically simpler, less expensive, and less error-prone than conventional spray methods. Further, the use of individual internal reinforcing members or reinforcements provides superior mechanical reinforcement compared to the sprayed external reinforcements of conventional spray methods. Also, by separating the spray process and the reinforcement, the present disclosure provides superior control over the surface thickness of the integrated components (including making the surface thickness vary as defined in the present application) compared to conventional spray methods.

[0067] Unless otherwise specified, any of the embodiments described herein as being incorporated into or used in a particular type of vehicle (e.g., an aircraft or helicopter) is understood to be applicable and usable in other types of vehicles (e.g., trains, submarines, tanks, armored personnel carriers, ships, etc.). The embodiments of the present disclosure are very suitable for manufacturing replacement parts for aircraft as described in this application, and can extend the life of the aircraft to the maximum extent at low cost. Cold spray has been recognized by various groups as an advantageous solution distinct from thermal spraying.

[0068] In particular, when an aircraft enters the end of its repeatedly extended life, inevitable flight fatigue causes cracks and other damages, necessitating structural repairs, component replacements, and component repairs to keep the aircraft in service. This drives up the cost of keeping the aircraft flying due to frequent inspections to maintain airworthiness, final modifications, and long lead times and high costs associated with supply chain issues. Cold spray is very suitable for generating replacement parts to restore aircraft, has the potential to significantly reduce maintenance inspection costs, and can also shorten the downtime of military aircraft platforms. The US Department of Defense approved and published MIL Spec MIL-STD-3021 (DEPARTMENT OF DEFENSE MANUFACTURING PROCESS STANDARD: MATERIALS DEPOSITION, COLD SPRAY) in 2008 (revised in 2011 and 2015). The MIL-STD-3021 standard has also been adopted by various other groups around the world.

[0069] The present disclosure is usable in a number of current military and civilian cold spray applications. Such applications particularly include, but are not limited to, the manufacture and replacement of magnesium aerospace components, the manufacture and replacement of the hydraulic systems of landing gear, and the manufacture and replacement of non-aerospace components.

[0070] Compared to conventional cold spray methods, the present disclosure enables the manufacture of more complex parts having multiple radii of curvature and reinforcements integrated within. The present disclosure is applicable to a wide variety of parts across numerous fields of endeavor. In particular, the present disclosure is particularly applicable to the manufacture of parts in the automotive and aerospace industries that require the manufacture of reinforced CMCPs. In some embodiments, it is possible to manufacture complex structures that would require the manufacture and assembly of multiple parts as a single integrated CMCP of the present disclosure. This integration significantly reduces costs and simplifies the supply chain. In some embodiments, the integrated parts manufactured are a permanently integrated single structure and not an assembly of separable sub-parts.

[0071] At least a portion of the functionality of the various elements in the figures is, in some embodiments, performed by other elements in the figures or other things not shown (e.g., a computer).

[0072] In some embodiments, the steps shown in FIGS. 4 - 7 are performed by one human, by a group of humans, by a fully or partially automated CSAM system, or by a combination thereof. By way of example, in some embodiments, the mold 100 and the reinforcement member 112 of FIG. 1 are provided from separate suppliers to a completely different assembler who combines the reinforcement member 112 with the mold 100.

[0073] Although aspects of the present disclosure have been described with respect to various embodiments and related processes, those skilled in the art should understand that combinations of processes from various different embodiments are also within the scope of the aspects of the present disclosure.

[0074] Exemplary Operating Environments The present disclosure can be used in a method for manufacturing and maintaining an aircraft according to one embodiment as method 900 of FIG. 9. During the aircraft manufacturing preparation stage, in some embodiments, method 900 includes the aircraft specifications and design of step 902 and material procurement of step 904. During the manufacturing stage, in some embodiments, method 900 includes the manufacturing of parts and subassemblies of step 906 and aircraft system integration of step 908. The aircraft obtains certification and delivery in step 910 and takes flight in step 912. During flight by the customer, a schedule for regular maintenance inspections of the aircraft is established in step 914. In some embodiments, step 914 includes other steps related to making changes, reconfiguring, retrofitting, and maintaining an acceptable and safe state of the aircraft during flight. The system and method for cold spray additive manufacturing of the present disclosure are used during step 914.

[0075] Each step of method 900 can be executed or implemented by a system integrator, a third party, or an operator (e.g., a customer). For the purposes of the present disclosure, examples of system integrators include various aircraft manufacturers and major system subcontractors. Examples of third parties include various vendors, subcontractors, and suppliers. Examples of operators include airlines, leasing companies, the military, maintenance inspection providers, and entities that provide similar sales and leasing services.

[0076] The present disclosure can be used in various terrestrial and extraterrestrial environments for a variety of applications. Exemplary operating environments are given below, but this is for illustrative purposes only and does not limit the operating environments in which embodiments of the present disclosure are expected to be used. The present disclosure can be used in an aircraft operating environment according to one embodiment as the aircraft 1000 in FIG. 10. The aircraft 1000 of the embodiment includes, but is not limited to, a fuselage 1002, a plurality of high-level systems 1004, and an interior 1006. Examples of high-level systems included in the aircraft 1000 of some embodiments include, but are not limited to, one or more of a propulsion system 1008, an electrical system 1010, a hydraulic system 1012, and an environmental system 1014. Various other systems may also be included in the aircraft 1000 of the embodiment. Although aerospace-related embodiments are shown, the principles are also applicable to other industries such as the automotive and marine industries.

[0077] The present disclosure can be used in a computing device according to one embodiment as the functional block diagram 1100 in FIG. 11. In such an embodiment, the components of the computing device 1118 can be realized as part of an electronic device according to one or more embodiments described herein. The computing device 1118 includes one or more processors 1119, which can be a microprocessor, a controller, or other suitable type of processor for processing computer-executable instructions to control the operation of the electronic device. Platform software including an operating system 1120, or other suitable platform software, is provided to the device 1118 to enable application software 1121 to be executed on the device. According to one embodiment, the method for performing cold spray additive manufacturing of the present disclosure is at least partially implemented by software. According to other embodiments, the system 800 for performing cold spray additive manufacturing using a mold of the present disclosure is at least partially implemented by software.

[0078] Computer-executable instructions can be provided using any computer-readable medium accessible to computing device 1118. Examples of computer-readable media include, but are not limited to, computer storage media such as memory 1122 and communication media. Computer storage media such as memory 1122 includes volatile and non-volatile removable and non-removable media implemented in methods and technologies for storing information such as computer-readable instructions, data structures, program modules, and the like. Examples of computer storage media include RAM, ROM, EPROM, EEPROM, flash (registered trademark) memory, other memory technologies, CD-ROM, DVD, other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage, and other magnetic storage devices, or other non-transmission media that can be used to store information accessible to a computing device, but are not limited thereto. In contrast, communication media can embody computer-readable instructions, data structures, program modules, etc. in a modulated data signal such as a carrier wave or other carrier mechanism. As defined herein, computer storage media does not include communication media. Thus, computer storage media is not construed to be a signal carrier per se. A signal carrier itself is not an example of computer storage media. Although computer storage media (memory 1122) is illustrated within computing device 1118, those skilled in the art will appreciate that storage can be distributed or remotely located and accessible via a network or other communication link (e.g., using communication interface 1123).

[0079] The computing device 1118 may include an input / output controller 1124 configured to output information to one or more output devices 1125 (in some embodiments, a display or a speaker), and can be separate from or integrated with the electronic device. Further, the input / output controller 1124 may also be configured to receive and process inputs from one or more input devices (in some embodiments, a keyboard, a microphone, a touch pad). In one embodiment, the output device 1125 may also function as an input device, and a touch-sensitive display is an example of such a device. Also, the input / output controller 1124 may output data to devices other than the output devices, for example, a locally connected printing device. In some embodiments, a user may provide an input to the input device 1126 and / or receive an output from the output device 1125.

[0080] The functions described in this application can be at least partially implemented by one or more hardware logic components. According to one embodiment, the computing device 1118 is composed of program code, and when executed by the processor 1119, it executes the steps and functions of the embodiments described in this application. Alternatively or additionally, the functions described in this application can be at least partially executed by one or more hardware logic components. Non-limiting and exemplary types of available hardware logic components include field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), application-specific standard products (ASSPs), system-on-chips (SOCs), complex programmable logic devices (CPLDs), and graphics processing units (GPUs).

[0081] Accordingly, various embodiments include an apparatus, a method, and a product for performing a method for cold spray additive manufacturing, the method comprising configuring a mold to have a first part and a second part, forming a gap along a longitudinal direction between the first part and the second part, shaping an outer surface of the first part engaged with the second part into a complex shape, disposing a reinforcing member within the gap, performing a first cold spray on (i) one of the first part and the second part and (ii) the reinforcing member, and performing a second cold spray on the other part to form an integrated component, wherein the reinforcing member becomes integral with the integrated component.

[0082] As described herein, the present disclosure provides an apparatus, a method, and a product for cold spray additive manufacturing of multiply curved reinforcement components. The systems and methods of the present disclosure are effectively and efficiently configured and installed in a CSAM system suitable for use in manufacturing multiply curved reinforcement components of various types of vehicles (including, but not limited to, the exemplary operating environments described above).

[0083] A variety of terms related to space and direction, such as upper, bottom, lower, middle, lateral, horizontal, vertical, front, etc., may be used to describe the present disclosure, but it should be understood that such terms are used only with respect to the orientation shown in the drawings. Such orientations can be reversed, rotated, or changed in other ways, such that the upper becomes the lower, or vice versa, or the horizontal becomes the vertical, etc.

[0084] In the present application, a structure, limitation, or element "configured" to perform a certain operation or process is formed, constructed, or adapted to a specific structure corresponding to that operation or process. It is made clear and without doubt that an object that can merely be changed to perform that operation or process is not "configured" to perform that operation or process in the present application.

[0085] The ranges and numerical values given in the present application can be extended or changed, as understood by those skilled in the art, without losing the intended effects.

[0086] Although the subject matter has been described in terms of structural features and / or methodological acts, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as exemplary forms for carrying out the claims.

[0087] It should be understood that the above advantages may relate to one embodiment or multiple embodiments. An embodiment is not limited to addressing all the problems considered in the background of the present application, nor is it limited to having any or all of the described advantages.

[0088] Embodiments of the present disclosure, as well as embodiments not specifically disclosed in the present application but within the scope of the claims, constitute exemplary means for cold spray additive manufacturing having a gas recovery function.

[0089] The order in which the steps of the embodiments of the present disclosure are performed or implemented is not important unless otherwise specified. That is, unless otherwise specified, the steps can be performed in any order, and the examples of the present disclosure can include more or fewer steps than those described in the present application. As an example, it is within the scope of the aspects of the present disclosure to perform or implement a specific step before, simultaneously with, or after other steps.

[0090] The description in the singular when explaining an element of an aspect or embodiment of the present disclosure means that there is one or more of that element. The descriptions "comprising", "including", and "having" are inclusive, meaning that additional elements other than the recited elements may exist. The description "exemplary" means "an example". The description "one or more of A, B, and C" means "at least one A, and / or, at least one B, and / or, at least one C".

[0091] While aspects of the present disclosure have been described in detail, it will be apparent that modifications and changes can be made without departing from the scope of the aspects of the present disclosure as defined in the appended claims. Since various changes can be made to the above configurations, products, and methods without departing from the scope of the aspects of the present disclosure, all matters included in this specification and shown in the accompanying drawings are to be regarded as illustrative and not restrictive.

[0092] It should be understood that the above description is illustrative and not restrictive. As an example, the above-described embodiments (and / or aspects) can be used in combination with each other. Also, numerous modifications can be made to adapt the teachings of the various embodiments of the present disclosure to specific situations and materials without departing from the scope of the present disclosure. The dimensions and types of materials described in the present application are for defining the parameters of the various embodiments of the present disclosure, but those embodiments are not restrictive and are exemplary embodiments. Many other embodiments will be apparent to those skilled in the art upon reading the above description. Therefore, the scope of the various embodiments of the present disclosure is determined by reference to the appended claims, along with the full scope of equivalents of the claims. In the appended claims, the terms "comprising," "being," are used as being equivalent to the general meanings of "including," "here," respectively. Further, the terms "first," "second," "third," are used merely as marks and do not impose numerical limitations on the object. Furthermore, the limitations in the appended claims are not written in means-plus-function form and are not construed based on 35 U.S.C. § 112(f) unless the limitation explicitly uses the term "means for" and continues with a functional recitation without specifying a structure.

[0093] This specification discloses, by way of example, various embodiments of the present disclosure, including the best mode, and enables those skilled in the art to make and use various embodiments of the present disclosure, including manufacturing and using devices and systems and performing related methods. The patentable scope of the various embodiments of the present disclosure is defined by the claims, and also includes other examples that would be assumed by those skilled in the art. Such other examples are within the scope of the claims when the examples have structural elements that do not differ from the literal language of the claims, or when the examples include equivalent structural elements that do not substantially differ from the literal language of the claims.

[0094] Further aspects are described in the following sections.

[0095] The set of item A Item A1 A mold for cold spray additive manufacturing, comprising: A first part; A second part (the first part and the second part are configured to engage adjacent to each other such that a gap is formed in the longitudinal direction therebetween, and the outer surface of the first part engaged with the second part has a complex shape); A reinforcing member located within the gap (the first part, the second part, and the reinforcing member are configured to be cold sprayed so as to form an integrated component, and the reinforcing member becomes integral with the integrated component). Item A2 The mold according to item A1, wherein the gap is formed by a cutout in one of the first part and the second part. Item A3 The mold according to item A1 or item A2, wherein the cutout extends only along a sub-section on one side of the first part or the second part, and forms a ridge extending longitudinally along the sub-section. Item A4 The mold according to any one of items A1 to A3, wherein the complex shape has a plurality of different curvatures. Item A5 The mold according to any one of items A1 to A4, wherein the reinforcing member is a flat reinforcing material. Item A6 The mold according to any one of items A1 to A5, wherein the integrated component formed by cold spray further comprises at least one surface portion with a varying thickness. Item A7 Segments of the reinforcement member extend from the outer surface of the integrated component, The mold according to any one of items A1 to A6, wherein the segments are machined to be flush with the outer surface of the integrated component. Item A8 The mold according to any one of items A1 to A7, further comprising a support device configured to support the reinforcement member within the gap. Item A9 The mold according to any one of items A1 to A8, wherein the support device comprises at least one of a fastener, a vacuum suction portion, and a magnetic coupling portion. Item A10 The mold according to any one of items A1 to A9, further comprising a support member positioned to support the reinforcement member within the gap.

[0096] Set of item B Item B1 A method for performing cold spray additive manufacturing, comprising: Configuring a mold to have a first part, a second part, a gap formed longitudinally between the first part and the second part, and an outer surface of the first part that engages the second part to form a complex shape; Placing a reinforcement member within the gap; (i) Performing a first cold spray on one of the first part and the second part, and (ii) performing a second cold spray on the other part to form an integrated component such that the reinforcement member becomes integral with the integrated component. A method comprising: Item B2 The method according to item B1, wherein the mold comprises an outer surface having a plurality of different curvatures. Item B3 The method according to item B1 or B2, wherein the reinforcement member is a flat reinforcing material. Item B4 The method according to any one of claims B1 to B3, wherein the first cold spray and the second cold spray produce at least one surface on the integrated component with a varying thickness. Claim B5 The method according to any one of claims B1 to B4, further comprising machining a segment of the reinforcing member extending from the outer surface of the integrated component so as to be flush with the outer surface of the integrated component. Claim B6 The method according to any one of claims B1 to B5, further comprising supporting a reinforcing member in the gap using a support device. Claim B7 The method according to any one of claims B1 to B6, wherein the support device comprises at least one of a fastener, a vacuum suction part, and a magnetic coupling part. Claim B8 The method according to any one of claims B1 to B7, further comprising arranging a support member to support the support member in the gap.

[0097] Group of Claim C Claim C1 An integrated component manufactured by a cold spray additive manufacturing method, wherein the cold spray additive manufacturing method comprises: configuring a mold to have a first part, a second part, a gap formed longitudinally between the first part and the second part, and an outer surface of the first part that engages with the second part to form a complex shape; placing a reinforcing member in the gap; (i) performing a first cold spray on one of the first part and the second part and (ii) the reinforcing member; performing a second cold spray on the other part to form the integrated component and causing the reinforcing member to be integrated with the integrated component. Claim C2 The integrated component according to claim C1, wherein the first cold spray and the second cold spray produce at least one surface portion on the integrated component with a varying thickness.

Description of the Reference Numerals

[0098] 100 molds The first part of mold 102 The second part of mold 104 106 gap The outer surface of the first part of the mold 110 complex shape 112 reinforcing member 150 integrated component

Claims

1. A mold (100) for cold spray additive manufacturing, comprising: a first part (102), a second part (104), wherein the first part (102) and the second part (104) are configured to engage adjacent to each other such that a gap (106) is formed along the longitudinal direction between the first part (102) and the second part (104), and the outer surface (108) of the first part (102) engaged with the second part (104) has a complex shape (110); further comprising a reinforcing member (112) positioned within the gap (106), wherein cold spray is performed such that the first part (102), the second part (104), and the reinforcing member (112) form an integrated component (150), and the reinforcing member (112) is configured to be integral with the integrated component (150); A mold (100), wherein segments (124) of the reinforcing member (112) extend from the outer surface (154) of the integrated component (150).

2. The mold (100) according to claim 1, wherein the gap (106) is formed by a cutout (114) in one of the first part (102) and the second part (104), the cutout (114) extending only along a sub-section (116) on one side of the first part (102) or the second part (104), and forming a ridge (120) extending longitudinally along the sub-section (116).

3. The mold (100) according to claim 1, wherein the complex shape (110) comprises a plurality of different curved portions (122).

4. The mold (100) according to claim 1, wherein the reinforcing member (112) is one of a flat reinforcement and a curved reinforcement.

5. The mold (100) according to claim 1, wherein the integrated component (150) formed by the cold spray comprises at least one surface portion with a varying thickness.

6. The mold (100) according to claim 1, wherein the segments (124) are machined to be flush with the outer surface (154) of the integrated component (150).

7. The mold (100) according to claim 1, further comprising a support device (126) configured to support the reinforcing member (112) within the gap (106), the support device (126) comprising at least one of a fastener, a vacuum suction portion, and a magnetic coupling portion.

8. The mold (100) according to claim 1, further comprising a support member (128) positioned to support the reinforcing member (112) within the gap (106).

9. A method (400) for performing cold spray additive manufacturing, comprising: configuring a mold (100) to have a first part (102), a second part (104), a gap (106) formed along a longitudinal direction between the first part (102) and the second part (104), and an outer surface (108) of the first part (102) that engages the second part (104) to form a complex shape (110); placing a reinforcing member (112) within the gap (106); performing a first cold spray on (i) one of the first part (102) and the second part (104) and (ii) the reinforcing member (112); performing a second cold spray on the other of the first part (102) and the second part (104) to form an integrated component (150) such that the reinforcing member (112) becomes integral with the integrated component (150).

10. The method (400) according to claim 9, wherein the first cold spray and the second cold spray create at least one surface portion of varying thickness on the integrated component (150).

11. The method (400) according to claim 9, further comprising machining segments (124) of the reinforcing member (112) that extend from an outer surface (154) of the integrated component (150) to be flush with the outer surface (154) of the integrated component (150).

12. The method (400) according to claim 9, further comprising supporting the reinforcing member (112) within the gap (106) using a support device (126).

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