System and method for forming a metallic component

Abstract

A system and method for electroforming a metallic component includes injecting an electrolytic solution from an injection manifold through set of injection nozzles into a bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow extending from the injection manifold to an anode, to a cathode and to a fluid outlet duct.

Description

TECHNICAL FIELD

[0001] The disclosure generally relates to metallic components and, more particularly, relates to a system and method for electroforming a metallic component.BACKGROUND

[0002] Turbine engines are rotary engines that extract energy from a flow of working air. The working air passes serially through a compressor section, a combustor section, and a turbine section. The compressor section compresses the working air. The combustor section adds fuel to, and ignites, the pressurized air. The turbine section expands and extracts work from the working air to drive the compressor section along with other systems, and provides thrust. The compressor and turbine stages comprise axially arranged pairs of sets of rotating blades and stationary vanes. The sets of rotating blades are circumferentially arranged about an engine centerline.

[0003] The fan blades are exposed to the atmosphere in front of the engine and have the potential for an impact with a bird or other foreign object that may be drawn into the engine. For this reason, a turbine fan blade typically includes a metallic component such as a fan blade shield for structural reinforcement to protect the fan blade from impacts such as a bird strike or the like. Such metallic components can be formed by an electroforming process.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] In the drawings:

[0005] FIG. 1 is a schematic cross-sectional view of a turbine engine according to an exemplary aspect of the present disclosure.

[0006] FIG. 2A is a schematic illustration of a system for forming a metallic component according to an exemplary aspect of the present disclosure.

[0007] FIG. 2B is a cross-section taken along line II-II of FIG. 2A.

[0008] FIG. 3 is a flow diagram of a method of forming a metallic component, according to an exemplary aspect of the present disclosure.DETAILED DESCRIPTION

[0009] The present disclosure relates to a method and system for forming a metallic component. More specifically, the disclosure relates to a method and system for electroforming a metallic component which provides improved wall thickness control with reduced porosity and pitting of the metallic component over conventional methods and systems.

[0010] For purposes of illustration, the aspects of the disclosure discussed herein will be described in terms of a fan blade shield for a gas turbine engine fan blade. It will be understood, however, that the disclosure as discussed herein is not so limited and may have general applicability to electroforming any desired metallic component, used in any desired application including non-aircraft applications, such as other mobile applications and non-mobile industrial, commercial, and residential applications without departing from the scope of the disclosure.

[0011] Reference will now be made in detail to various aspects, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings.

[0012] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Additionally, unless specifically identified otherwise, all aspects described herein should be considered exemplary.

[0013] As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components, unless otherwise noted.

[0014] The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Furthermore, as used herein, the term “set” or a “set” of elements can be any number of elements, including only one.

[0015] The term “fluid” may be a gas or a liquid, or multi-phase. The term “fluid communication” means that a fluid is capable of making the connection between the areas specified.

[0016] As used herein, the term “electrodeposition rate” refers to a speed at which metal ions are reduced and deposited onto a substrate. An electrodeposition rate in a system can be affected by many factors, including, but not limited to an electric field intensity within the electrolytic solution, anode material, cathode material, electrolytic solution properties such as ion concentration, conductivity, resistivity, temperature, viscosity, pH level, chemical stability, additives, impurities, and the like.

[0017] As used herein, the term “integral monolithic body” or “monolithic body” means a single body that is a single, non-separable piece, or formed as a single unitary piece at manufacture, as opposed to being formed by combining separate elements into one during manufacture.

[0018] As used herein, the term “upstream” refers to a direction that is opposite the fluid flow direction, and the term “downstream” refers to a direction that is in the same direction as the fluid flow.

[0019] The term “fore” or “forward” means in front of something and “aft” or “rearward” means behind something. For example, with regard to a turbine engine, forward refers to a position closer to an engine inlet and aft refers to a position closer to an engine nozzle or exhaust.

[0020] Additionally, as used herein, the terms “radial” or “radially” refer to a dimension away from a common center. For example, in the overall context of a turbine engine, radial refers to a direction along a ray extending between a center longitudinal axis of the engine and an outer engine circumference.

[0021] All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of aspects of the disclosure described herein.

[0022] Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate structural elements between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order, and relative sizes reflected in the drawings attached hereto can vary.

[0023] Conventional gas turbine engines can include a fan section having airfoils. The airfoils may include fan blades and / or outlet guide vanes, for example. Conventional fan blades are typically made of low-density metals, such as aluminum, or composite materials to decrease their weight.

[0024] During operation of the gas turbine engine, (e.g., during a flight), foreign objects may become entrained in an inlet of the gas turbine engine, and can strike the fan blades, causing damage to the fan blade. For example, foreign objects may include birds, rain, hailstones, ice or other debris. Strikes by relatively large objects (e.g., birds) may rupture the blades, resulting in blade fragments flying radially outward at high velocity. Additionally, strikes by relatively smaller foreign objects (e.g., sand) can progressively erode the blade.

[0025] One known solution to reduce the damage to fan blades due to strikes by foreign objects is to attach a respective metallic edge guard or shield to the leading edge of each fan blade. The fan blade shield, sometimes called a metal leading edge (MLE) shield may help provide erosion or impact protection for the fan blade and particularly for its leading edge. The fan blade shields also allow the energy of the impact to be transmitted through the shield over a larger area than the impact position.

[0026] Conventional fan blade shields are typically formed at least in part of a material that includes a metal alloy. For example, the fan blade shields can be formed from materials such as titanium and nickel metals or alloys thereof. These metallic materials have enhanced physical properties, including toughness, flexural modulus, bulk modulus, hardness, elasticity, or ductility, and combinations thereof, which can provide better strength and ductility when compared with the low-density metals or composite materials used to form the fan blade itself. These enhanced material properties of the fan blade shields typically provide enhanced energy absorption in the event of a strike from airborne debris.

[0027] Titanium alloys thereof provide high strength to weight ratios, good temperature and chemical resistance, and relative low densities, which make them ideal to be used as fan blade shields. But titanium alloys are extremely difficult to machine using conventional grinding tools, and costs associated with their machining are high due to a short tool life. One known solution to the high machining costs is to fabricate the fan blade shields by an electroforming process.

[0028] In conventional electroforming processes, a cathode (e.g., a negatively charged electrode), in the form of a mandrel or an article to be plated as a substrate, is immersed in a suitable electrolytic solution and an electrical current (e.g. a plating current) is passed through the electrolytic solution between a suitable anode (e.g., a positively charged electrode) to the cathode. The electrolytic solution typically contains one or more metal salts, such as copper sulfate, to facilitate an electrical current therethrough. The passage of the electrical current through the electrolytic solution causes the article to be electroformed on the cathode with a desired metal or alloy finish. The anode and cathode are placed in the electrolytic solution and electrically coupled to a power supply, which creates an electric field in the electrolytic solution between the anode and cathode, and supplies a direct current (DC) flow to the anode. This electrical current causes the metal to oxidize, allowing metal atoms of the anode to dissolve in the electrolytic solution as positive metal ions. The electrical current then causes the metal ions to move from the positively charged anode to the negatively charged cathode and deposit onto the mandrel or cathode in a thin layer of metal.

[0029] Typically, the anode has the same general composition as the metal (e.g., titanium) or alloy which is to be deposited on the mandrel. The anode material is dissolved by electrochemical action to continuously replenish the metallic content of the electrolytic solution which is consumed as a result of plating or forming on the article. The anode material typically serves the dual function of simultaneously completing an electrical circuit between the anode and cathode, and replenishing the metallic content of the electrolytic solution.

[0030] Typically, a composite structure, commonly referred to as a “basket”, which is electrically conductive but chemically inert with respect to the electrolytic solution is used to support or contain the anode material. The anode material can be formed as relatively small pieces (sometimes referred to as coins or billets or the like) arranged in electrical contact with each other and with the electrically conductive anode basket. The anode basket is typically suspended in the electrolytic solution from an electrically conductive support bar or other support structure. The electrolytic solution is in fluid communication with the anode material contained therein through openings provided in the anode basket. In operation, the anode material can be gradually consumed and replaced as necessary at appropriate intervals.

[0031] For example, in one particular example of a fan blade shield to be formed by a conventional electroforming process, a die or mandrel, can have an exterior surface formed of an electrically conductive material such as titanium. The mandrel exterior surface can conform to a fan blade's airfoil configuration minus the thickness of the fan blade shield to be electroformed on the mandrel. A desired thicknesses of the fan blade shield also can be achieved by a well-known process of “shielding”, in which a non-conductive barrier wall or “cathode shield” is placed adjacent the mandrel to influence or direct the electrical current through the electrolytic solution between the anode and the cathode. After the mandrel has been left in the electrolytic solution under the influence of an electric field for a pre-determined length of time, the mandrel is removed. The electrodeposited material on the exterior surface of the mandrel is mechanically removed from the mandrel as a newly electroformed fan blade shield. The fan blade shield can then be machined to smoothly fit over a respective fan blade, in a manner well-known in the art.

[0032] However, conventional fan blade shields for gas turbine engines are typically limited in that a thickness range ratio, defined by a ratio of the thickness of the thickest part of the shield (e.g., a leading edge of the shield) to the thickness of the thinnest part of the shield (e.g., a trailing edge of the shield), is generally 5:1, and may reach 10:1 at a greater cost. However, increasing strength requirements for modern fan blades can require this ratio be as high as, for example, 80:1. These requirements require close tolerances and plating uniformity, and thus present problems for the electroforming method fan blade shields.

[0033] For example, one problem with conventional electroforming methods is that, in many cases, during operation, as the individual pieces of anode material gradually decrease in size over time, voids are created in the anode material due to bridging of individual anode pieces. Such bridging prevents the anode material from settling to the bottom of the anode basket as the anode material is consumed, and thus prevents the formation of sufficient room for the addition of new anode material to the anode basket. The bridging also results in a variable quantity of anode material in contact with the electrolytic solution over time resulting in poor uniformity of the deposited material and increased porosity or pitting on the electroformed surface.

[0034] One known solution to overcome anode bridging is to agitate the anode basket to cause the anode pieces to settle to the bottom thereof, in order to permit proper refilling of the anode basket. Typically, agitation of the anode basket to settle anode material is done either manually, (e.g., shaking the basket) or by using a mechanical or motorized mechanism to shake or shock the anode basket to cause settling of the anode material. Such techniques and / or mechanisms can add additional costs, and in some cases can result in damage to the basket.

[0035] Additionally, conventional cathode shields placed between the anode and cathode, while advantageous to influence or direct the electrical current through the electrolytic solution from the anode and the cathode, can result in an uneven flow of ions through the electrolytic solution, resulting in an uneven deposition of anode material onto the cathode.

[0036] To better address challenges raised by the gas turbine industry requiring tight tolerances on electroformed metallic components to produce reliable and high-performance gas turbines, it is therefore desirable to provide an improved system and method of electroforming fan blade shields, with improved operational efficiency and reasonable cost. Advantageously, the aspects as disclosed herein provide an electroforming system that includes a fluid pump and an injection manifold including a set of nozzles, arranged to cooperatively inject an electrolytic fluid flow, flowing from the anode toward the cathode to advantageously enable a controlled flow of ions through the electrolytic solution, and further enable improved control of the thickness of the electroformed metallic component over conventional techniques. Furthermore, the electrolytic fluid flow can agitate, dislodge, or otherwise remove gas bubbles (e.g., hydrogen) that may have formed on the cathode surface during the electroforming operation, beneficially enabling decreased pitting and porosity of the metallic component over conventional methods. The decreased porosity afforded by the aspects disclosed herein can enhance aerodynamic performance of the metallic component when used as a fan blade shield. Additionally, aspects as disclosed herein can reduce anode bridging without need of a mechanical agitator.

[0037] FIG. 1 is a schematic cross-sectional diagram of a gas turbine engine 10 for an aircraft. The gas turbine engine 10 has a generally longitudinally extending axis or engine centerline 12 extending forward 14 to aft 16. The gas turbine engine 10 includes, in downstream serial flow relationship, a fan section 18 including a fan 20, a compressor section 22 including a booster or low pressure (LP) compressor 24 and a high pressure (HP) compressor 26, a combustion section 28 including a combustor 30, a turbine section 32 including a HP turbine 34, and an LP turbine 36, and an exhaust section 38.

[0038] The fan section 18 includes a fan casing 40 surrounding the fan 20. The fan 20 includes a plurality of fan blades 42 disposed radially about the engine centerline 12. The fan 20 can have any suitable configuration, such as a variable pitch, single stage configuration. The fan blades 42 can be coupled to a fan disk 41 in a circumferentially spaced apart manner. The fan blades 42 may extend outwardly from the fan disk 41 generally along a radial direction. The fan blades 42 may be formed at least in part from a composite material, such as a carbon-fiber material. Additionally, or in the alternative, the fan blades 42 may be formed at least in part from a metallic alloy.

[0039] The fan blades 42 incorporate an airfoil adapted to effectively move air, having a leading edge 43a and trailing edge 43b. The fan blades 42 may include a hub end 42a attached to the fan disk 41 and a remote end 42b away from the hub end 42a. Further, the fan blades 42 may have a respective fan blade shield 37 that extends from the remote end 42b to the hub end 42a along a leading edge 43a of the fan blade 42. It is noted that the fan blade shield 37 is curved and has a twist from the remote end 42b to the hub end 42a, matching the geometry of the leading edge 43a of the fan blade 42. The fan blade shield 37 can be attached to at least part of the leading edge of the fan blade 42.

[0040] The fan blade shield 37 may provide protection from damage, such as from impacts, erosion, and the like. A fan blade shield 37 may be formed at least in part using an additive manufacturing technology, using any suitable metal alloy or non-metallic material, such as those described herein. In non-limiting aspects, the fan blade shield 37 may have a monolithic structure.

[0041] A fan inlet 83 of the fan section 18 is defined at the upstream or forward end 14 of the gas turbine engine 10. A fan exhaust 84 is defined at the downstream end of the fan casing 40. The HP compressor 26, the combustor 30, and the HP turbine 34 form an engine core 44 of the gas turbine engine 10, which generates combustion gases. The engine core 44 is surrounded by a core casing 46, which can be coupled with the fan casing 40.

[0042] A HP shaft or spool 48 disposed coaxially about the engine centerline 12 of the gas turbine engine 10 drivingly connects the HP turbine 34 to the HP compressor 26. A LP shaft or spool 50, which is disposed coaxially about the engine centerline 12 of the gas turbine engine 10 within the larger diameter annular HP spool 48, drivingly connects the LP turbine 36 to the LP compressor 24 and fan 20. The spools 48, 50 are rotatable about the engine centerline 12 and couple to a plurality of rotatable elements, which can collectively define a rotor 51.

[0043] The LP compressor 24 and the HP compressor 26 respectively include a plurality of compressor stages 52, 54, in which a set of compressor blades 56, 58 rotate relative to a corresponding set of static compressor vanes 60, 62 (also called a nozzle) to compress or pressurize the stream of fluid passing through the stage. In a single compressor stage 52, 54, multiple compressor blades 56, 58 can be provided in a ring and can extend radially outwardly relative to the engine centerline 12, from a blade platform to a blade tip, while the corresponding compressor vanes 60, 62 are positioned upstream of and adjacent to the rotating blades 56, 58. It is noted that the number of blades, vanes, and compressor stages shown in FIG. 1 were selected for illustrative purposes only, and that other numbers are possible.

[0044] The blades 56, 58 for a stage of the compressor can be mounted to a compressor disk 61, which is mounted to the corresponding one of the HP and LP spools 48, 50, with each stage having its own compressor disk 61. The blades 56, 58 may be part of a blisk, rather than being mounted to a disk. The vanes 60, 62 for a stage of the compressor can be mounted to the core casing 46 in a circumferential arrangement.

[0045] The HP turbine 34 and the LP turbine 36 respectively include a plurality of turbine stages 64, 66, in which a set of turbine blades 68, 70 are rotated relative to a corresponding nozzle 73, 75 including respective sets of static turbine vanes 72, 74, to extract energy from the stream of fluid passing through the turbine stage 64, 66. In a single turbine stage 64, 66, multiple turbine blades 68, 70 can be provided in a ring and can extend radially outwardly relative to the engine centerline 12, from a blade platform to a blade tip, while the corresponding turbine vanes 72, 74 are positioned upstream of and adjacent to the rotating turbine blades 68, 70. The turbine blades 68, 70 and the turbine vanes 72, 74 can be airfoil shaped. It is noted that the number of blades, vanes, and turbine stages shown in FIG. 1 were selected for illustrative purposes only, and that other numbers are possible.

[0046] The turbine blades 68, 70 for a stage of the turbine can be mounted to a turbine disk 71, which is mounted to the corresponding one of the HP and LP spools 48, 50, with each stage having a dedicated turbine disk 71. The vanes 72, 74 for a stage of the compressor can be mounted to the core casing 46 in a circumferential arrangement.

[0047] Complimentary to the rotor portion, the stationary portions of the gas turbine engine 10, such as the vanes 60, 62, 72, 74 among the compressor and turbine sections 22, 32 are also referred to individually or collectively as a stator 63. As such, the stator 63 can refer to the combination of non-rotating elements throughout the gas turbine engine 10.

[0048] In operation, the airflow exiting the fan section 18 is split such that a portion of the airflow is channeled into the LP compressor 24, which then supplies pressurized airflow 76 to the HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from the HP compressor 26 is mixed with fuel in the combustor 30 and ignited, thereby generating combustion gases. Some work is extracted from these gases by the HP turbine 34, which drives the HP compressor 26. The combustion gases are discharged into the LP turbine 36, which extracts additional work to drive the LP compressor 24, and the exhaust gas is ultimately discharged from the gas turbine engine 10 via the exhaust section 38. The driving of the LP turbine 36 drives the LP spool 50 to rotate the fan 20 and the LP compressor 24.

[0049] A portion of the airflow exiting the fan section, called a bypass airflow 78, bypasses the LP compressor 24 and engine core 44 and exits the gas turbine engine 10 through a stationary vane row, and more particularly an outlet guide vane assembly 80, comprising a plurality of airfoil guide vanes 82, at the fan exhaust 84. More specifically, a circumferential row of radially extending airfoil guide vanes 82 are utilized adjacent the fan section 18 to exert some directional control of the bypass airflow 78.

[0050] Some of the air supplied by the fan 20 can bypass the engine core 44 and be used for cooling of portions, especially hot portions, of the gas turbine engine 10, and / or used to cool or power other aspects of the aircraft. In the context of a turbine engine, the hot portions of the engine are normally downstream of the combustor 30, especially the turbine section 32 which is directly downstream of the combustion section 28. Other sources of cooling fluid can be, but are not limited to, fluid discharged from the LP compressor 24 or the HP compressor 26.

[0051] FIG. 2A depicts a block diagram of non-limiting aspect of a system 110 for carrying out an electroforming process for forming a metallic component 138 as disclosed herein. The system 110 can include an electrodeposition bath 140 having a bath tank 145 containing an electrolytic solution 148. The electrolytic solution 148 is electrically conductive. The bath tank 145 can include a fluid inlet duct 141 and a fluid outlet duct 142. The system 110 can further include an injection manifold 150 defining a set of openings or injection nozzles 159. As illustrated, an anode 160 including an anodic material 160a (shown in FIG. 2B), a cathode 180, and the injection manifold 150 can be submersed or disposed in the electrolytic solution 148. The anode 160 is spaced from the cathode 180. In non-limiting aspects, a cathode shield 170 can be disposed between and spaced from the anode 160 and the cathode 180. For example, the anode 160 is disposed between the injection manifold 150 and the cathode shield 170. Any number of mechanical brackets, supports, or hangers 146 can be used to position the injection manifold 150, anode 160, cathode shield 170, and cathode 180 in the bath tank 145 as desired. The system 110 can further include a fluid pump 147. An electrical power supply 190 (e.g., a direct current electrical power supply) can be disposed outside of the bath tank 145 and electrically coupled to the anode 160 and the cathode 180.

[0052] The bath tank 145 carries the electrolytic solution 148. In non-limiting aspects, the electrolytic solution 148 can include aluminum alloy carrying alloying metal ions. In another non-limiting example, the electrolytic solution 148 can include a nickel alloy carrying alloying metal ions. In non-limiting aspects, the bath tank 145 can be fabricated from suitably acid-resistant material such as polyethylene, polypropylene, fluoropolymers (e.g., Teflon® or polyvinylidene fluoride (PVDF)).

[0053] The fluid pump 147 is fluidly coupled with the fluid inlet duct 141 and the fluid outlet duct 142 to arrange an electrolytic fluid flow (indicated by the series of arrows “149”) of the electrolytic solution 148 within the bath tank 145. The fluid inlet duct 141 is coupled in fluid communication with the injection manifold 150 to provide the electrolytic solution 148 thereto. The fluid outlet duct 142 is arranged in fluid communication with the electrolytic solution 148 disposed in the bath tank 145 to receive the electrolytic fluid flow 149 therefrom.

[0054] In non-limiting aspects, the fluid inlet duct 141 is arranged at a first end (e.g., a bottom) of the bath tank 145, with the fluid outlet duct 142 disposed at an opposing second end (e.g., a top) of the bath tank 145. For example, as illustrated, the fluid inlet duct 141 can be located at a lower portion of the bath tank 145, below the anode 160, and the fluid outlet duct 142 can be located at an upper portion of the bath tank 145, above the cathode 180. It is contemplated that other aspects are not so limited, and the fluid inlet duct 141 and the fluid outlet duct 142 can be arranged or oriented with respect to each other in a variety of ways as desired to enable the electrolytic fluid flow 149 to flow, from upstream to downstream, from the fluid inlet duct 141, to the injection manifold 150, to the anode 160, to the cathode shield 170, to the cathode 180, and to the fluid outlet duct 142. In some non-limiting aspects, for example, the orientation within the bath tank 145 of the anode 160 and cathode 180 can be reversed (e.g., with the anode 160 oriented at the second end (e.g., the top) of the bath tank 145, and the cathode 180 oriented at the first end (e.g., the bottom) and the electrolytic fluid flow 149 arranged to flow from the second end toward the first end of the bath tank 145. In other non-limiting aspects, for example, the anode 160 and cathode 180 can be arranged vertically and spaced from each other (e.g., from left to right or vice versa) with the electrolytic fluid flow 149 arranged to flow horizontally within the bath tank 145.

[0055] The fluid pump 147 can circulate or re-cycle the electrolytic solution 148 through the bath tank 145 via the fluid inlet duct 141 and fluid outlet duct 142. In some non-limiting aspects, a filter 143 can optionally be provided to filter and chemically maintain the electrolytic solution 148 at a particular ion concentration, or to remove any foreign matter. The filter 143 can include, by way of non-limiting example, a chemical filtering media. Optionally, a heater 144 can be provided to regulate the temperature of the electrolytic solution 148 in the bath tank 145. In non-limiting examples, the heater 144 can be disposed within the bath tank 145 or proximate the bath tank 145 exterior to the bath tank 145. Alternatively, the heater 144 can be in fluid communication with the fluid pump 147 to heat the electrolytic solution 148 as the electrolytic solution 148 is pumped by the fluid pump 147.

[0056] The electrical power supply 190, which can include a controller (not shown), can be electrically coupled to the anode 160 and the cathode 180 by electrical conduits 191 to form a circuit 192 via the electrolytic solution 148. The electrical power supply 190 can operatively create an electric field 193 across the electrolytic solution 148 between the anode 160 and cathode 180. Optionally, a switch (not shown) or sub-controller can be included along the electrical conduits 191, and can be positioned between the electrical power supply 190 and the anode 160 and cathode 180. The electrical power supply 190 can be configured to provide an electrical current 195 (illustrated as dashed arrows) to the anode 160 (e.g. a plating current) which can flow through the electrolytic solution 148 from the anode 160 to the cathode 180. The electrical current 195 can cause metal ions to move from the anode 160 to the cathode 180 and deposit thereon.

[0057] FIG. 2B depicts a cross-section of the system 110 taken along the line II-II of FIG. 2A, with some parts omitted for clarity. The injection manifold 150 can at least one wall 150a arranged to define a manifold interior 158. The at least one wall 150a can further define the set of injection nozzles 159 therethrough. As such, the manifold interior 158 defines a passageway for the electrolytic fluid flow 149, in fluid communication with the set of injection nozzles 159. The injection manifold 150 is coupled in fluid communication to the fluid inlet duct 141 (FIG. 2A) to receive the electrolytic fluid flow 149 therefrom. In this way, the electrolytic fluid flow 149 can be arranged to flow, from upstream to downstream, from the fluid inlet duct 141 to the injection manifold 150, then radially outward through the set of injection nozzles 159 into the bath tank 145 toward the anode 160.

[0058] The anode 160 can be a sacrificial anode or an inert anode. While one anode 160 is shown, it should be understood that the bath tank 145 can include any number of anodes 160 as desired. The anode 160 can be arranged to define a container, or anode basket 165. The anodic material 160a can be supported by, or housed within, the anode basket 165. In some aspects, the anodic material 160a can be in the form of, without limitation, a set of spheres, pellets, discs, cubes, flakes, or any other desired geometric shape including amorphous.

[0059] The anode basket 165 can be formed of an electrically conductive metal (e.g., titanium) that is not soluble in the electrolytic solution 148 and is capable of holding a positive voltage potential to allow metal ions to be liberated from the anodic material 160a contained therein. In non-limiting aspects, the anode basket 165 can include a set of walls 164 arranged to define a basket interior 167 therebetween. For example, each wall 164 can have a first inward-facing surface 164a facing the basket interior 167, and an opposing outward-facing surface 164b facing an exterior of the anode basket 165. The anode basket 165 can also include a floor or bottom 166. The bottom 166 can define a set of first apertures 166a therethrough, arranged to allow an ingress of the electrolytic fluid flow 149 therethrough from the exterior of the anode basket 165 to the basket interior 167 and through or past the anodic material 160a. In some aspects, the bottom 166 can further provide or define a support surface for the anodic material 160a. The first apertures 166a can be smaller than anodic material 160a to prevent ingress of the anodic material 160a into the first apertures 166a. While the first apertures 166a are illustrated in the example of FIG. 2B as being generally cylindrical, and having substantially the same size and orientation as each other, other aspects are not so limited. It is contemplated that in other aspects the size, shape, and relative orientation of the first apertures 166a can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic, including for example, velocity and direction of the electrolytic fluid flow 149, without departing from the scope of the disclosure.

[0060] In non-limiting aspects, the anode basket 165 can also include a ceiling or cover 169. The cover 169 can define a set of second apertures 169a therethrough, arranged to allow an egress of the electrolytic fluid flow 149 therethrough from the basket interior 167 to the exterior of the anode basket 165. While the second apertures 169a are illustrated in the example of FIG. 2B as being generally cylindrical, and having substantially the same size and orientation as each other, other aspects are not so limited. It is contemplated that in other aspects, the size, shape, and relative orientation of the second apertures 169a can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic including, for example, a velocity and a direction of the electrolytic fluid flow 149, without departing from the scope of the disclosure. It is further contemplated that in other aspects, the cover 169 can be omitted, such that the anode basket 165 has an open top. In some aspects, one or more of the walls 164 can define a respective set of third apertures 164c therethrough to allow ingress or egress, or both, of the electrolytic solution 148.

[0061] The cathode shield 170 is disposed in the bath tank 145 between the anode 160 and the cathode 180. The cathode shield 170 can define a cathode shield body 171. In non-limiting aspects, the cathode shield body 171 can define a set of cathode shield apertures 176 therethrough. The cathode shield apertures 176 can be sized and oriented to receive the electrolytic fluid flow 149 therethrough. It is contemplated that in various aspects, the cathode shield 170 can define any desired number of cathode shield apertures 176. The cathode shield apertures 176 can be axially spaced from each other along a length of the cathode shield 170. For example, in non-limiting aspects the cathode shield apertures 176 can be spaced apart in a row along an axial length of the cathode shield 170. At least a subset of the set of cathode shield apertures 176 can be aligned (e.g., with respect to a direction of the electrolytic fluid flow 149) with the cathode 180. The set of cathode shield apertures 176 can be sized and arranged to control, direct or guide a velocity, or a direction, or both, of the electrolytic fluid flow 149.

[0062] The cathode shield 170 can be formed of an electrically non-conductive or ionically resistive material. In non-limiting aspects, the cathode shield 170 can be formed of a dielectric material including, but not limited to polymers, glasses, and ceramics. For example, the cathode shield 170 can be made of polyethylene, polypropylene, fluoropolymers (e.g., Teflon® or PVDF), and the like.

[0063] In non-limiting aspects, the cathode 180 can include a mandrel 182. The mandrel 182 can include an exterior metallic layer 183 (e.g., an outer coating). For example, in non-limiting aspects, the exterior metallic layer 183 can be formed of, without limitation, copper, silver, or nickel. It is contemplated that the exterior metallic layer 183 can be formed on the mandrel 182 via a spray, painting, coating, or similar treatment to facilitate formation of the cathode 180.

[0064] The mandrel 182 can be formed (e.g., by molding, machining, additive manufacturing, etc.) in a shape corresponding to a desired shape of metallic component 138. The mandrel 182 includes a mandrel body 185 formed from, by way of non-limiting example, a reclaimable material. For example, the mandrel body 185 can be made of a reclaimable material that can be collected after an electroforming process and reused as another body in another electroforming process. Suitable reclaimable materials can include waxes, plastics, polymer foams, metals, or deformable materials, such as those materials that are collectible via melting or leaching in non-limiting examples. After completion of the electroforming process, the mandrel body 185 can be reclaimed from the electroformed component, such as through heating and melting of the mandrel body 185 at heightened temperatures, to reclaim the structural material.

[0065] In operation, the bath tank 145 can contain a suitable amount or level of the electrolytic solution 148, sufficient to cover or immerse the injection manifold 150, anode basket 165, and cathode 180. The fluid pump 147 can operate to circulate the electrolytic solution 148 through the bath tank 145 from the fluid inlet duct 141 to the fluid outlet duct 142. The electrolytic solution 148 flows into the injection manifold 150 and is injected from the set of injection nozzles 159 toward the anode 160 to define the electrolytic fluid flow 149. The electrolytic fluid flow 149 can flow through the first apertures 166a, and through gaps or spaces defined between and around the anode material 160a contained in the anode basket 165. In non-limiting aspects, the electrolytic fluid flow 149 can then flow from the anode 160 toward the cathode shield 170. The cathode shield 170 can partially block, impede, or redirect a portion of the electrolytic fluid flow 149, while allowing another portion of the electrolytic fluid flow 149 to flow around the cathode shield body 171, and / or through the set of cathode shield apertures 176 defined therethrough to flow toward the cathode 180.

[0066] The electrical power supply 190, can operatively create the electric field 193 across the electrolytic solution 148 between the anode 160 and cathode 180. The electric field 193 can cause the electrical current 195 to flow through the electrolytic solution 148 from the anode 160 to the cathode 180. The electrical current 195 can cause metal ions from the anode material 160a (e.g., tungsten) to move from the anode 160 to the cathode 180 and deposit onto the mandrel 182 to form the metallic component 138. In a non-limiting example, the metallic component 138 can be a fan blade shield 37.

[0067] An electrodeposition rate of the anode material 160a at a particular region of the cathode 180 will depend in part on a variety of factors, including characteristics of the electrolytic solution fluid flow 149, the electric field 193, the electrical current 195 through the electrolytic solution 148 between the anode 160 and the cathode 180, and the characteristics of the electrolytic fluid flow 149 at any given point or region on the cathode 180. For example, in non-limiting aspects, a thickness profile of the electrodeposited metal ions on the mandrel 182 can be selectively controlled at least in part by configuring the size, shape, orientation, and combinations thereof, of the cathode shield 170 and cathode shield apertures 176, to modulate the electric field 193 or guide the electrolytic fluid flow 149, or both, or a combination thereof.

[0068] The cathode shield 170 can be arranged and disposed to mask predetermined points or portions of the surface of the cathode 180 from the electrical current 195 and / or the electrolytic fluid flow 149. For example, since the cathode shield 170 is electrically non-conductive (e.g., formed of a dielectric material) an intensity of the electric field 193, between the anode 160 and each given point on the cathode 180 can be selectively varied or modulated by the presence of the cathode shield 170. Furthermore, the shape, size, and location of the cathode shield body 171 within the electrolytic fluid flow 149, as well as the size, quantity, and location of the cathode shield apertures 176 can affect the characteristics (e.g., velocity and direction) of the electrolytic fluid flow 149 with respect to the cathode 180.

[0069] It is expected that exterior regions of the cathode 180 having an unmasked (e.g., not masked by the cathode shield 170) surface area will experience a relatively higher charge transfer rate than exterior regions of the cathode 180 having a masked (e.g., by the cathode shield 170) surface area. Therefore, the electrodeposition rate (and thus the thickness profile of the electrodeposited metal) can be controlled by appropriately shaping the cathode shield 170 and configuring the cathode shield apertures 176 to arrange a desired characteristic (e.g., velocity and direction) of the electrolytic fluid flow 149.

[0070] Additionally, or alternatively, in non-limiting aspects, the characteristics of the electrolytic fluid flow 149 can be controlled by adjusting the velocity of the electrolytic fluid flow 149, or the direction of the electrolytic fluid flow 149, or both. For example, in non-limiting aspects, the fluid pump 147 can be configured to increase or decrease the velocity of the electrolytic fluid flow 149 in the fluid inlet duct 141, or injection manifold 150, or both. In some non-limiting aspects, the velocity of the electrolytic fluid flow 149 or the direction of the electrolytic fluid flow 149, or both, through the bath tank 145 can be further controlled by configuring the set of injection nozzles 159 as desired.

[0071] Of course, the actual thickness profile of the electrodeposited metal will additionally depend on the various parameters used in the electroplating process (e.g., the metal used, the voltage and current applied, the concentration, temperature, flow and type of the additives and components in the bath tank 145).

[0072] FIG. 3 illustrates a method 300 for forming the metallic component 138. The method 300 is provided for illustrative purposes and may proceed in a different logical order or additional or intervening steps may be included, unless otherwise noted. While the method 300 is described in the context of the system 110 depicted in FIGS. 2A-2B, for forming the metallic component 138 by electrodeposition onto a mandrel 182, the method 300 may be used in a similar manner to form other types of bodies using other suitable forms.

[0073] The method 300 begins at 310 with disposing an electrolytic solution 148 into a bath tank 145 having a fluid inlet duct 141 and a fluid outlet duct 142, the fluid inlet duct 141 and the fluid outlet duct 142 fluidly coupled with the electrolytic solution 148.

[0074] In non-limiting aspects, the electrolytic solution 148 can include aluminum alloy carrying alloying metal ions. In another non-limiting example, the electrolytic solution 148 can include a nickel alloy carrying alloying metal ions. In non-limiting aspects, the bath tank 145 can be fabricated from suitably acid-resistant material such as polyethylene, polypropylene, fluoropolymers (e.g., Teflon® or PVDF).

[0075] The method 300 can include, at 315, immersing an injection manifold 150 including the set of injection nozzles 159 in the electrolytic solution 148 in the bath tank 145. In non-limiting aspects, the injection manifold 150 can include a body having at least one wall 150a arranged to define a manifold interior 158. The at least one wall 150a can further define the set of openings or injection nozzles 159 therethrough. In non-limiting aspects, the manifold interior 158 can define a passageway for an electrolytic solution fluid flow 149, in fluid communication with the set of injection nozzles 159.

[0076] The method 300 can include, at 320, fluidly coupling the injection manifold 150 to the fluid inlet duct 141, and at 325, coupling a fluid pump 147 in fluid communication to the fluid outlet duct 142 to receive the electrolytic solution 148 therefrom.

[0077] The method 300 can further include, at 330, coupling the fluid pump 147 in fluid communication to the fluid inlet duct 141 to provide the electrolytic solution 148 thereto. In some non-limiting aspects, a filter 143 can optionally be provided to filter and chemically maintain the electrolytic solution 148 at a particular ion concentration, or to remove any foreign matter. The filter 143 can include, by way of non-limiting example, a chemical filtering media. Optionally, a heater 144 can be provided to regulate a temperature of the electrolytic solution 148 in the bath tank 145. In non-limiting examples, the heater 144 can be disposed within the bath tank 145 or proximate the bath tank 145 exterior to the bath tank 145. Alternatively, the heater 144 can be in fluid communication with the fluid pump 147 to heat the electrolytic solution 148 as it is pumped by the fluid pump 147.

[0078] The method 300 can include, at 335, fluidly pumping the electrolytic solution 148 from the fluid inlet duct 141 to the injection manifold 150. The method 300 can further include, at 340, injecting the electrolytic solution 148 from the injection manifold 150 into the bath tank 145 to define an electrolytic fluid flow 149 within the bath tank 145, the electrolytic fluid flow 149 extending from the injection manifold 150 to the fluid outlet duct 142. In non-limiting aspects, the electrolytic fluid flow 149 can be arranged to flow, from upstream to downstream, from the fluid inlet duct 141 to the injection manifold 150, then radially outward through the set of injection nozzles 159 into the bath tank 145 toward an anode 160. For example, in non-limiting aspects, the fluid inlet duct 141 and the fluid outlet duct 142 can be arranged or oriented with respect to each other in a variety of ways as desired to enable the electrolytic fluid flow 149 to flow, from upstream to downstream, from the fluid inlet duct 141, to the injection manifold 150, to the anode 160, to a cathode 180, and to the fluid outlet duct 142.

[0079] The method 300 can include, at 345, disposing the anode 160 in the bath tank 145 downstream of the injection manifold 150. The anode 160 can be a sacrificial anode or an inert anode. The anode 160 can include an anodic material 160a. In some exemplary aspects, the anodic material 160a can be in the form of, without limitation, a set of spheres, pellets, discs, cubes, flakes, or any other desired geometric shape including amorphous.

[0080] In non-limiting aspects, the anodic material 160a can be disposed in an anode basket 165. The anode basket 165 can be formed of an electrically conductive metal (e.g., titanium) that is not soluble in the electrolytic solution 148 and is capable of holding a positive voltage potential and allowing metal ions to be liberated from the anodic material 160a contained therein. In non-limiting aspects, the anode basket 165 can include a body having a set of walls 164 arranged to define a basket interior 167 therebetween. For example, each wall 164 can have a first inward-facing surface 164a facing the basket interior 167, and an opposing send outward-facing surface 164b facing an exterior of the anode basket 165. The anode basket 165 can also include a floor or bottom 166. The bottom 166 can define a set of first apertures 166a therethrough, arranged to allow an ingress of the electrolytic fluid flow 149 therethrough from the exterior of the anode basket 165 to the basket interior 167 and through or past the anodic material 160a. In some aspects, the bottom 166 can further provide or define a support surface for the anodic material 160a. The first apertures 166a can be smaller than anodic material 160a to prevent ingress of the anodic material 160a into the first apertures 166a. In non-limiting aspects, the size, shape, and relative orientation of the first apertures 166a can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic, including velocity and direction of the electrolytic fluid flow 149.

[0081] In non-limiting aspects, the anode basket 165 can also include a ceiling or cover 169. The cover 169 can define a set of second apertures 169a therethrough, arranged to allow an egress of the electrolytic fluid flow 149 therethrough from the basket interior 167 to the exterior of the anode basket 165. In non-limiting aspects, the size, shape, and relative orientation of the second apertures 169a can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic including a velocity and a direction of the electrolytic fluid flow 149, without departing from the scope of the disclosure. In other aspects, the cover 169 can be omitted, such that the anode basket has an open top. In some aspects, one or more of the walls 164 can define a respective set of third apertures 164c therethrough to allow ingress or egress or both of the electrolytic solution 148.

[0082] The method 300 can include, at 350, disposing a cathode 180 in the bath tank 145 downstream of the anode 160. In non-limiting aspects, the cathode 180 can be a mandrel 182 having exterior metallic layer 183 (e.g., an exterior coating. For example, in non-limiting aspects, the exterior metallic layer 183 can be formed of, without limitation, copper, silver, or nickel. In non-limiting aspects, the exterior metallic layer 183 can be applied to the mandrel 182 via a spray, painting, coating, or similar treatment to facilitate formation of the cathode 180.

[0083] The mandrel 182 can include a mandrel body 185 formed from, by way of non-limiting example, a reclaimable material. For example, the mandrel body 185 can be made of a reclaimable material that can be collected after an electroforming process and reused as another body in another electroforming process. Suitable reclaimable materials can include waxes, plastics, polymer foams, metals, or deformable materials, such as those materials that are collectible via melting or leaching in non-limiting examples. After completion of the electroforming process, the mandrel body 185 can be reclaimed from the electroformed component, such as through heating and melting of the mandrel body 185 at heightened temperatures, to reclaim the structural material. The mandrel 182 can define or correspond to the shape of the metallic component 138.

[0084] The method 300 can include, at 355, electrically coupling the electrical power supply 190 to the anode 160 and the cathode 180 to provide an electrical current 195 therebetween through the electrolytic solution 148. The electrical power supply 190, can be electrically coupled to the anode 160 and the cathode 180 by electrical conduits 191 to form a circuit 192 via the electrolytic solution 148. The electrical power supply 190 can operatively create an electric field 193 across the electrolytic solution 148 between the anode 160 and the cathode 180. The electrical current 195 can cause metal ions to move from the anode 160 to the cathode 180 and deposit onto the mandrel 182.

[0085] In non-limiting aspects, the method 300 can optionally include, at 360, disposing a cathode shield 170 in the bath tank 145 between the anode 160 and the cathode 180. The cathode shield 170 can be formed of an electrically non-conductive or ionically resistive material. In non-limiting aspects, the cathode shield 170 can be formed of a dielectric material including, but not limited to polymers, glasses, and ceramics. For example, the cathode shield 170 can be made of polyethylene, polypropylene, fluoropolymers (e.g., Teflon® or PVDF), and the like.

[0086] In non-limiting aspects, the cathode shield 170 includes a cathode shield body 171 defining a set of cathode shield apertures 176 therethrough. The cathode shield apertures 176 can be sized and oriented to receive the electrolytic fluid flow 149 therethrough. The cathode shield apertures 176 can be axially spaced from each other along a length of the cathode shield 170. At least a subset of the set of cathode shield apertures 176 can be aligned (e.g., with respect to a direction of the electrolytic fluid flow 149) with the cathode 180. The set of cathode shield apertures 176 can be sized and arranged to control, direct or guide a velocity, or a direction, or both, of the electrolytic fluid flow 149.

[0087] Advantageously, the method 300 described herein allows improved control of the thickness of the electroformed metallic component over conventional techniques. Furthermore, the method 300 provides for generating a metallic component that has a decreased porosity over conventional methods. The decreased porosity afforded by the method 300 can enhance aerodynamic performance of the metallic component when used as a fan blade shield 37. Additionally, the system 110 and method 300 as disclosed herein can reduce anode bridging without need of a mechanical agitator. Overall, this manufacturing process simplification reduces time, cost, and defects, and can provide for an overall improvement in the final product, such as increased smoothness, reduced porosity, or controlled thickness, and combinations thereof, as compared with that of a similar metallic component formed by a different method. Additionally, the system 110 and method 300 as disclosed herein enables improved thickness control and profile control over conventional systems and methods for example by providing a controlled flow of electrons and a controlled electrolytic solution fluid flow.

[0088] To the extent not already described, the different features and structures of the various aspects can be used in combination with each other as desired. That one feature cannot be illustrated in all of the aspects is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different aspects can be mixed and matched as desired to form new examples, whether or not the new examples are expressly described. Combinations or permutations of features described herein are covered by this disclosure. Many other possible aspects and configurations in addition to that shown in the above figures are contemplated by the present disclosure.

[0089] This written description uses examples to describe aspects of the disclosure described herein, including the best mode, and also to enable any person skilled in the art to practice aspects of the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of aspects of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

[0090] Further aspects of the disclosure are provided by the subject matter of the following clauses:

[0091] A system for electroforming a metallic component, comprising: a bath tank configured to hold an electrolytic solution, the bath tank having a fluid inlet duct and a fluid outlet duct, the fluid inlet duct and the fluid outlet duct fluidly coupled with the electrolytic solution; a fluid pump coupled in fluid communication to the fluid inlet duct to provide the electrolytic solution thereto, and coupled in fluid communication to the fluid outlet duct to receive the electrolytic solution therefrom; an injection manifold coupled in fluid communication to the fluid inlet duct to receive the electrolytic solution therefrom, the injection manifold including a set of injection nozzles configured to inject the electrolytic solution therefrom into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow extending from the injection manifold to the fluid outlet duct; an anode disposed in the bath tank downstream of the injection manifold with respect to the electrolytic solution fluid flow; a cathode disposed in the bath tank downstream of the anode with respect to the electrolytic solution fluid flow; and an electrical power supply electrically coupled to the anode and the cathode to provide an electrical current therebetween through the electrolytic solution in the bath tank.

[0092] The system of any preceding clause, wherein the injection nozzles are axially spaced from each other along a length of the injection manifold.

[0093] The system of any preceding clause, wherein the anode includes an anode basket, configured to support an anodic material, the anode basket defining a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

[0094] The system of any preceding clause, wherein the anode basket is formed from an electrically conductive material.

[0095] The system of any preceding clause, further comprising a cathode shield, including a cathode shield body formed of a dielectric material, the cathode shield disposed in the bath tank between the anode and the cathode, in fluid communication with the electrolytic solution fluid flow.

[0096] The system of any preceding clause, wherein the cathode shield includes a set of cathode shield apertures defined therethrough, the cathode shield apertures configured to receive the electrolytic solution fluid flow therethrough.

[0097] The system of any preceding clause, wherein the cathode includes a mandrel.

[0098] The system of any preceding clause, wherein the mandrel is formed with a reclaimable material.

[0099] The system of any preceding clause, wherein the mandrel includes an exterior metallic layer.

[0100] The system of any preceding clause, wherein the bath tank includes a heater configured to heat the electrolytic solution.

[0101] The system of any preceding clause, wherein the metallic component is a fan blade shield for a fan blade.

[0102] A method of electroforming a metallic component, the method comprising: disposing an electrolytic solution into a bath tank having a fluid inlet duct and a fluid outlet duct, the fluid inlet duct and the fluid outlet duct fluidly coupled with the electrolytic solution; immersing an injection manifold including a set of injection nozzles in the electrolytic solution in the bath tank; coupling the injection manifold in fluid communication with the fluid inlet duct; coupling a fluid pump in fluid communication with the fluid outlet duct to receive the electrolytic solution therefrom; coupling the fluid pump in fluid communication with the fluid inlet duct to provide the electrolytic solution thereto; pumping the electrolytic solution from the fluid inlet duct to the injection manifold; injecting the electrolytic solution from the injection manifold into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow extending from the injection manifold to the fluid outlet duct; disposing an anode in the bath tank downstream of the injection manifold with respect to the electrolytic solution fluid flow; disposing a cathode in the bath tank downstream of the anode with respect to the electrolytic solution fluid flow; and electrically coupling a power supply to the anode and the cathode to provide an electrical current therebetween through the electrolytic solution.

[0103] The method of any preceding clause, wherein the injection nozzles are axially spaced from each other along a length of the injection manifold.

[0104] The method of any preceding clause, wherein the anode includes an anode basket configured to support an anodic material, the anode basket defining a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

[0105] The method of any preceding clause, wherein the anode basket is formed from an electrically conductive material.

[0106] The method of any preceding clause, further comprising disposing a cathode shield having a cathode shield body formed of a dielectric material in the bath tank between the anode and the cathode, in fluid communication with the electrolytic solution fluid flow.

[0107] The method of any preceding clause, wherein the cathode shield includes a set of cathode shield apertures defined therethrough, the cathode shield apertures configured to receive the electrolytic solution fluid flow therethrough.

[0108] The method of any preceding clause, wherein the cathode includes a mandrel formed with a reclaimable material.

[0109] The method of any preceding clause, wherein the bath tank includes a heater configured to heat the electrolytic solution.

[0110] The method of any preceding clause, wherein the metallic component is a shield for a fan blade.

Examples

Embodiment Construction

[0009]The present disclosure relates to a method and system for forming a metallic component. More specifically, the disclosure relates to a method and system for electroforming a metallic component which provides improved wall thickness control with reduced porosity and pitting of the metallic component over conventional methods and systems.

[0010]For purposes of illustration, the aspects of the disclosure discussed herein will be described in terms of a fan blade shield for a gas turbine engine fan blade. It will be understood, however, that the disclosure as discussed herein is not so limited and may have general applicability to electroforming any desired metallic component, used in any desired application including non-aircraft applications, such as other mobile applications and non-mobile industrial, commercial, and residential applications without departing from the scope of the disclosure.

[0011]Reference will now be made in detail to various aspects, one or more examples of w...

TECHNICAL FIELD

[0001] The disclosure generally relates to metallic components and, more particularly, relates to a system and method for electroforming a metallic component.BACKGROUND

[0002] Turbine engines are rotary engines that extract energy from a flow of working air. The working air passes serially through a compressor section, a combustor section, and a turbine section. The compressor section compresses the working air. The combustor section adds fuel to, and ignites, the pressurized air. The turbine section expands and extracts work from the working air to drive the compressor section along with other systems, and provides thrust. The compressor and turbine stages comprise axially arranged pairs of sets of rotating blades and stationary vanes. The sets of rotating blades are circumferentially arranged about an engine centerline.

[0003] The fan blades are exposed to the atmosphere in front of the engine and have the potential for an impact with a bird or other foreign object that may be drawn into the engine. For this reason, a turbine fan blade typically includes a metallic component such as a fan blade shield for structural reinforcement to protect the fan blade from impacts such as a bird strike or the like. Such metallic components can be formed by an electroforming process.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] In the drawings:

[0005] FIG. 1 is a schematic cross-sectional view of a turbine engine according to an exemplary aspect of the present disclosure.

[0006] FIG. 2A is a schematic illustration of a system for forming a metallic component according to an exemplary aspect of the present disclosure.

[0007] FIG. 2B is a cross-section taken along line II-II of FIG. 2A.

[0008] FIG. 3 is a flow diagram of a method of forming a metallic component, according to an exemplary aspect of the present disclosure.DETAILED DESCRIPTION

[0009] The present disclosure relates to a method and system for forming a metallic component. More specifically, the disclosure relates to a method and system for electroforming a metallic component which provides improved wall thickness control with reduced porosity and pitting of the metallic component over conventional methods and systems.

[0010] For purposes of illustration, the aspects of the disclosure discussed herein will be described in terms of a fan blade shield for a gas turbine engine fan blade. It will be understood, however, that the disclosure as discussed herein is not so limited and may have general applicability to electroforming any desired metallic component, used in any desired application including non-aircraft applications, such as other mobile applications and non-mobile industrial, commercial, and residential applications without departing from the scope of the disclosure.

[0011] Reference will now be made in detail to various aspects, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings.

[0012] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Additionally, unless specifically identified otherwise, all aspects described herein should be considered exemplary.

[0013] As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components, unless otherwise noted.

[0014] The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Furthermore, as used herein, the term “set” or a “set” of elements can be any number of elements, including only one.

[0015] The term “fluid” may be a gas or a liquid, or multi-phase. The term “fluid communication” means that a fluid is capable of making the connection between the areas specified.

[0016] As used herein, the term “electrodeposition rate” refers to a speed at which metal ions are reduced and deposited onto a substrate. An electrodeposition rate in a system can be affected by many factors, including, but not limited to an electric field intensity within the electrolytic solution, anode material, cathode material, electrolytic solution properties such as ion concentration, conductivity, resistivity, temperature, viscosity, pH level, chemical stability, additives, impurities, and the like.

[0017] As used herein, the term “integral monolithic body” or “monolithic body” means a single body that is a single, non-separable piece, or formed as a single unitary piece at manufacture, as opposed to being formed by combining separate elements into one during manufacture.

[0018] As used herein, the term “upstream” refers to a direction that is opposite the fluid flow direction, and the term “downstream” refers to a direction that is in the same direction as the fluid flow.

[0019] The term “fore” or “forward” means in front of something and “aft” or “rearward” means behind something. For example, with regard to a turbine engine, forward refers to a position closer to an engine inlet and aft refers to a position closer to an engine nozzle or exhaust.

[0020] Additionally, as used herein, the terms “radial” or “radially” refer to a dimension away from a common center. For example, in the overall context of a turbine engine, radial refers to a direction along a ray extending between a center longitudinal axis of the engine and an outer engine circumference.

[0021] All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of aspects of the disclosure described herein.

[0022] Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate structural elements between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order, and relative sizes reflected in the drawings attached hereto can vary.

[0023] Conventional gas turbine engines can include a fan section having airfoils. The airfoils may include fan blades and / or outlet guide vanes, for example. Conventional fan blades are typically made of low-density metals, such as aluminum, or composite materials to decrease their weight.

[0024] During operation of the gas turbine engine, (e.g., during a flight), foreign objects may become entrained in an inlet of the gas turbine engine, and can strike the fan blades, causing damage to the fan blade. For example, foreign objects may include birds, rain, hailstones, ice or other debris. Strikes by relatively large objects (e.g., birds) may rupture the blades, resulting in blade fragments flying radially outward at high velocity. Additionally, strikes by relatively smaller foreign objects (e.g., sand) can progressively erode the blade.

[0025] One known solution to reduce the damage to fan blades due to strikes by foreign objects is to attach a respective metallic edge guard or shield to the leading edge of each fan blade. The fan blade shield, sometimes called a metal leading edge (MLE) shield may help provide erosion or impact protection for the fan blade and particularly for its leading edge. The fan blade shields also allow the energy of the impact to be transmitted through the shield over a larger area than the impact position.

[0026] Conventional fan blade shields are typically formed at least in part of a material that includes a metal alloy. For example, the fan blade shields can be formed from materials such as titanium and nickel metals or alloys thereof. These metallic materials have enhanced physical properties, including toughness, flexural modulus, bulk modulus, hardness, elasticity, or ductility, and combinations thereof, which can provide better strength and ductility when compared with the low-density metals or composite materials used to form the fan blade itself. These enhanced material properties of the fan blade shields typically provide enhanced energy absorption in the event of a strike from airborne debris.

[0027] Titanium alloys thereof provide high strength to weight ratios, good temperature and chemical resistance, and relative low densities, which make them ideal to be used as fan blade shields. But titanium alloys are extremely difficult to machine using conventional grinding tools, and costs associated with their machining are high due to a short tool life. One known solution to the high machining costs is to fabricate the fan blade shields by an electroforming process.

[0028] In conventional electroforming processes, a cathode (e.g., a negatively charged electrode), in the form of a mandrel or an article to be plated as a substrate, is immersed in a suitable electrolytic solution and an electrical current (e.g. a plating current) is passed through the electrolytic solution between a suitable anode (e.g., a positively charged electrode) to the cathode. The electrolytic solution typically contains one or more metal salts, such as copper sulfate, to facilitate an electrical current therethrough. The passage of the electrical current through the electrolytic solution causes the article to be electroformed on the cathode with a desired metal or alloy finish. The anode and cathode are placed in the electrolytic solution and electrically coupled to a power supply, which creates an electric field in the electrolytic solution between the anode and cathode, and supplies a direct current (DC) flow to the anode. This electrical current causes the metal to oxidize, allowing metal atoms of the anode to dissolve in the electrolytic solution as positive metal ions. The electrical current then causes the metal ions to move from the positively charged anode to the negatively charged cathode and deposit onto the mandrel or cathode in a thin layer of metal.

[0029] Typically, the anode has the same general composition as the metal (e.g., titanium) or alloy which is to be deposited on the mandrel. The anode material is dissolved by electrochemical action to continuously replenish the metallic content of the electrolytic solution which is consumed as a result of plating or forming on the article. The anode material typically serves the dual function of simultaneously completing an electrical circuit between the anode and cathode, and replenishing the metallic content of the electrolytic solution.

[0030] Typically, a composite structure, commonly referred to as a “basket”, which is electrically conductive but chemically inert with respect to the electrolytic solution is used to support or contain the anode material. The anode material can be formed as relatively small pieces (sometimes referred to as coins or billets or the like) arranged in electrical contact with each other and with the electrically conductive anode basket. The anode basket is typically suspended in the electrolytic solution from an electrically conductive support bar or other support structure. The electrolytic solution is in fluid communication with the anode material contained therein through openings provided in the anode basket. In operation, the anode material can be gradually consumed and replaced as necessary at appropriate intervals.

[0031] For example, in one particular example of a fan blade shield to be formed by a conventional electroforming process, a die or mandrel, can have an exterior surface formed of an electrically conductive material such as titanium. The mandrel exterior surface can conform to a fan blade's airfoil configuration minus the thickness of the fan blade shield to be electroformed on the mandrel. A desired thicknesses of the fan blade shield also can be achieved by a well-known process of “shielding”, in which a non-conductive barrier wall or “cathode shield” is placed adjacent the mandrel to influence or direct the electrical current through the electrolytic solution between the anode and the cathode. After the mandrel has been left in the electrolytic solution under the influence of an electric field for a pre-determined length of time, the mandrel is removed. The electrodeposited material on the exterior surface of the mandrel is mechanically removed from the mandrel as a newly electroformed fan blade shield. The fan blade shield can then be machined to smoothly fit over a respective fan blade, in a manner well-known in the art.

[0032] However, conventional fan blade shields for gas turbine engines are typically limited in that a thickness range ratio, defined by a ratio of the thickness of the thickest part of the shield (e.g., a leading edge of the shield) to the thickness of the thinnest part of the shield (e.g., a trailing edge of the shield), is generally 5:1, and may reach 10:1 at a greater cost. However, increasing strength requirements for modern fan blades can require this ratio be as high as, for example, 80:1. These requirements require close tolerances and plating uniformity, and thus present problems for the electroforming method fan blade shields.

[0033] For example, one problem with conventional electroforming methods is that, in many cases, during operation, as the individual pieces of anode material gradually decrease in size over time, voids are created in the anode material due to bridging of individual anode pieces. Such bridging prevents the anode material from settling to the bottom of the anode basket as the anode material is consumed, and thus prevents the formation of sufficient room for the addition of new anode material to the anode basket. The bridging also results in a variable quantity of anode material in contact with the electrolytic solution over time resulting in poor uniformity of the deposited material and increased porosity or pitting on the electroformed surface.

[0034] One known solution to overcome anode bridging is to agitate the anode basket to cause the anode pieces to settle to the bottom thereof, in order to permit proper refilling of the anode basket. Typically, agitation of the anode basket to settle anode material is done either manually, (e.g., shaking the basket) or by using a mechanical or motorized mechanism to shake or shock the anode basket to cause settling of the anode material. Such techniques and / or mechanisms can add additional costs, and in some cases can result in damage to the basket.

[0035] Additionally, conventional cathode shields placed between the anode and cathode, while advantageous to influence or direct the electrical current through the electrolytic solution from the anode and the cathode, can result in an uneven flow of ions through the electrolytic solution, resulting in an uneven deposition of anode material onto the cathode.

[0036] To better address challenges raised by the gas turbine industry requiring tight tolerances on electroformed metallic components to produce reliable and high-performance gas turbines, it is therefore desirable to provide an improved system and method of electroforming fan blade shields, with improved operational efficiency and reasonable cost. Advantageously, the aspects as disclosed herein provide an electroforming system that includes a fluid pump and an injection manifold including a set of nozzles, arranged to cooperatively inject an electrolytic fluid flow, flowing from the anode toward the cathode to advantageously enable a controlled flow of ions through the electrolytic solution, and further enable improved control of the thickness of the electroformed metallic component over conventional techniques. Furthermore, the electrolytic fluid flow can agitate, dislodge, or otherwise remove gas bubbles (e.g., hydrogen) that may have formed on the cathode surface during the electroforming operation, beneficially enabling decreased pitting and porosity of the metallic component over conventional methods. The decreased porosity afforded by the aspects disclosed herein can enhance aerodynamic performance of the metallic component when used as a fan blade shield. Additionally, aspects as disclosed herein can reduce anode bridging without need of a mechanical agitator.

[0037] FIG. 1 is a schematic cross-sectional diagram of a gas turbine engine 10 for an aircraft. The gas turbine engine 10 has a generally longitudinally extending axis or engine centerline 12 extending forward 14 to aft 16. The gas turbine engine 10 includes, in downstream serial flow relationship, a fan section 18 including a fan 20, a compressor section 22 including a booster or low pressure (LP) compressor 24 and a high pressure (HP) compressor 26, a combustion section 28 including a combustor 30, a turbine section 32 including a HP turbine 34, and an LP turbine 36, and an exhaust section 38.

[0038] The fan section 18 includes a fan casing 40 surrounding the fan 20. The fan 20 includes a plurality of fan blades 42 disposed radially about the engine centerline 12. The fan 20 can have any suitable configuration, such as a variable pitch, single stage configuration. The fan blades 42 can be coupled to a fan disk 41 in a circumferentially spaced apart manner. The fan blades 42 may extend outwardly from the fan disk 41 generally along a radial direction. The fan blades 42 may be formed at least in part from a composite material, such as a carbon-fiber material. Additionally, or in the alternative, the fan blades 42 may be formed at least in part from a metallic alloy.

[0039] The fan blades 42 incorporate an airfoil adapted to effectively move air, having a leading edge 43a and trailing edge 43b. The fan blades 42 may include a hub end 42a attached to the fan disk 41 and a remote end 42b away from the hub end 42a. Further, the fan blades 42 may have a respective fan blade shield 37 that extends from the remote end 42b to the hub end 42a along a leading edge 43a of the fan blade 42. It is noted that the fan blade shield 37 is curved and has a twist from the remote end 42b to the hub end 42a, matching the geometry of the leading edge 43a of the fan blade 42. The fan blade shield 37 can be attached to at least part of the leading edge of the fan blade 42.

[0040] The fan blade shield 37 may provide protection from damage, such as from impacts, erosion, and the like. A fan blade shield 37 may be formed at least in part using an additive manufacturing technology, using any suitable metal alloy or non-metallic material, such as those described herein. In non-limiting aspects, the fan blade shield 37 may have a monolithic structure.

[0041] A fan inlet 83 of the fan section 18 is defined at the upstream or forward end 14 of the gas turbine engine 10. A fan exhaust 84 is defined at the downstream end of the fan casing 40. The HP compressor 26, the combustor 30, and the HP turbine 34 form an engine core 44 of the gas turbine engine 10, which generates combustion gases. The engine core 44 is surrounded by a core casing 46, which can be coupled with the fan casing 40.

[0042] A HP shaft or spool 48 disposed coaxially about the engine centerline 12 of the gas turbine engine 10 drivingly connects the HP turbine 34 to the HP compressor 26. A LP shaft or spool 50, which is disposed coaxially about the engine centerline 12 of the gas turbine engine 10 within the larger diameter annular HP spool 48, drivingly connects the LP turbine 36 to the LP compressor 24 and fan 20. The spools 48, 50 are rotatable about the engine centerline 12 and couple to a plurality of rotatable elements, which can collectively define a rotor 51.

[0043] The LP compressor 24 and the HP compressor 26 respectively include a plurality of compressor stages 52, 54, in which a set of compressor blades 56, 58 rotate relative to a corresponding set of static compressor vanes 60, 62 (also called a nozzle) to compress or pressurize the stream of fluid passing through the stage. In a single compressor stage 52, 54, multiple compressor blades 56, 58 can be provided in a ring and can extend radially outwardly relative to the engine centerline 12, from a blade platform to a blade tip, while the corresponding compressor vanes 60, 62 are positioned upstream of and adjacent to the rotating blades 56, 58. It is noted that the number of blades, vanes, and compressor stages shown in FIG. 1 were selected for illustrative purposes only, and that other numbers are possible.

[0044] The blades 56, 58 for a stage of the compressor can be mounted to a compressor disk 61, which is mounted to the corresponding one of the HP and LP spools 48, 50, with each stage having its own compressor disk 61. The blades 56, 58 may be part of a blisk, rather than being mounted to a disk. The vanes 60, 62 for a stage of the compressor can be mounted to the core casing 46 in a circumferential arrangement.

[0045] The HP turbine 34 and the LP turbine 36 respectively include a plurality of turbine stages 64, 66, in which a set of turbine blades 68, 70 are rotated relative to a corresponding nozzle 73, 75 including respective sets of static turbine vanes 72, 74, to extract energy from the stream of fluid passing through the turbine stage 64, 66. In a single turbine stage 64, 66, multiple turbine blades 68, 70 can be provided in a ring and can extend radially outwardly relative to the engine centerline 12, from a blade platform to a blade tip, while the corresponding turbine vanes 72, 74 are positioned upstream of and adjacent to the rotating turbine blades 68, 70. The turbine blades 68, 70 and the turbine vanes 72, 74 can be airfoil shaped. It is noted that the number of blades, vanes, and turbine stages shown in FIG. 1 were selected for illustrative purposes only, and that other numbers are possible.

[0046] The turbine blades 68, 70 for a stage of the turbine can be mounted to a turbine disk 71, which is mounted to the corresponding one of the HP and LP spools 48, 50, with each stage having a dedicated turbine disk 71. The vanes 72, 74 for a stage of the compressor can be mounted to the core casing 46 in a circumferential arrangement.

[0047] Complimentary to the rotor portion, the stationary portions of the gas turbine engine 10, such as the vanes 60, 62, 72, 74 among the compressor and turbine sections 22, 32 are also referred to individually or collectively as a stator 63. As such, the stator 63 can refer to the combination of non-rotating elements throughout the gas turbine engine 10.

[0048] In operation, the airflow exiting the fan section 18 is split such that a portion of the airflow is channeled into the LP compressor 24, which then supplies pressurized airflow 76 to the HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from the HP compressor 26 is mixed with fuel in the combustor 30 and ignited, thereby generating combustion gases. Some work is extracted from these gases by the HP turbine 34, which drives the HP compressor 26. The combustion gases are discharged into the LP turbine 36, which extracts additional work to drive the LP compressor 24, and the exhaust gas is ultimately discharged from the gas turbine engine 10 via the exhaust section 38. The driving of the LP turbine 36 drives the LP spool 50 to rotate the fan 20 and the LP compressor 24.

[0049] A portion of the airflow exiting the fan section, called a bypass airflow 78, bypasses the LP compressor 24 and engine core 44 and exits the gas turbine engine 10 through a stationary vane row, and more particularly an outlet guide vane assembly 80, comprising a plurality of airfoil guide vanes 82, at the fan exhaust 84. More specifically, a circumferential row of radially extending airfoil guide vanes 82 are utilized adjacent the fan section 18 to exert some directional control of the bypass airflow 78.

[0050] Some of the air supplied by the fan 20 can bypass the engine core 44 and be used for cooling of portions, especially hot portions, of the gas turbine engine 10, and / or used to cool or power other aspects of the aircraft. In the context of a turbine engine, the hot portions of the engine are normally downstream of the combustor 30, especially the turbine section 32 which is directly downstream of the combustion section 28. Other sources of cooling fluid can be, but are not limited to, fluid discharged from the LP compressor 24 or the HP compressor 26.

[0051] FIG. 2A depicts a block diagram of non-limiting aspect of a system 110 for carrying out an electroforming process for forming a metallic component 138 as disclosed herein. The system 110 can include an electrodeposition bath 140 having a bath tank 145 containing an electrolytic solution 148. The electrolytic solution 148 is electrically conductive. The bath tank 145 can include a fluid inlet duct 141 and a fluid outlet duct 142. The system 110 can further include an injection manifold 150 defining a set of openings or injection nozzles 159. As illustrated, an anode 160 including an anodic material 160a (shown in FIG. 2B), a cathode 180, and the injection manifold 150 can be submersed or disposed in the electrolytic solution 148. The anode 160 is spaced from the cathode 180. In non-limiting aspects, a cathode shield 170 can be disposed between and spaced from the anode 160 and the cathode 180. For example, the anode 160 is disposed between the injection manifold 150 and the cathode shield 170. Any number of mechanical brackets, supports, or hangers 146 can be used to position the injection manifold 150, anode 160, cathode shield 170, and cathode 180 in the bath tank 145 as desired. The system 110 can further include a fluid pump 147. An electrical power supply 190 (e.g., a direct current electrical power supply) can be disposed outside of the bath tank 145 and electrically coupled to the anode 160 and the cathode 180.

[0052] The bath tank 145 carries the electrolytic solution 148. In non-limiting aspects, the electrolytic solution 148 can include aluminum alloy carrying alloying metal ions. In another non-limiting example, the electrolytic solution 148 can include a nickel alloy carrying alloying metal ions. In non-limiting aspects, the bath tank 145 can be fabricated from suitably acid-resistant material such as polyethylene, polypropylene, fluoropolymers (e.g., Teflon® or polyvinylidene fluoride (PVDF)).

[0053] The fluid pump 147 is fluidly coupled with the fluid inlet duct 141 and the fluid outlet duct 142 to arrange an electrolytic fluid flow (indicated by the series of arrows “149”) of the electrolytic solution 148 within the bath tank 145. The fluid inlet duct 141 is coupled in fluid communication with the injection manifold 150 to provide the electrolytic solution 148 thereto. The fluid outlet duct 142 is arranged in fluid communication with the electrolytic solution 148 disposed in the bath tank 145 to receive the electrolytic fluid flow 149 therefrom.

[0054] In non-limiting aspects, the fluid inlet duct 141 is arranged at a first end (e.g., a bottom) of the bath tank 145, with the fluid outlet duct 142 disposed at an opposing second end (e.g., a top) of the bath tank 145. For example, as illustrated, the fluid inlet duct 141 can be located at a lower portion of the bath tank 145, below the anode 160, and the fluid outlet duct 142 can be located at an upper portion of the bath tank 145, above the cathode 180. It is contemplated that other aspects are not so limited, and the fluid inlet duct 141 and the fluid outlet duct 142 can be arranged or oriented with respect to each other in a variety of ways as desired to enable the electrolytic fluid flow 149 to flow, from upstream to downstream, from the fluid inlet duct 141, to the injection manifold 150, to the anode 160, to the cathode shield 170, to the cathode 180, and to the fluid outlet duct 142. In some non-limiting aspects, for example, the orientation within the bath tank 145 of the anode 160 and cathode 180 can be reversed (e.g., with the anode 160 oriented at the second end (e.g., the top) of the bath tank 145, and the cathode 180 oriented at the first end (e.g., the bottom) and the electrolytic fluid flow 149 arranged to flow from the second end toward the first end of the bath tank 145. In other non-limiting aspects, for example, the anode 160 and cathode 180 can be arranged vertically and spaced from each other (e.g., from left to right or vice versa) with the electrolytic fluid flow 149 arranged to flow horizontally within the bath tank 145.

[0055] The fluid pump 147 can circulate or re-cycle the electrolytic solution 148 through the bath tank 145 via the fluid inlet duct 141 and fluid outlet duct 142. In some non-limiting aspects, a filter 143 can optionally be provided to filter and chemically maintain the electrolytic solution 148 at a particular ion concentration, or to remove any foreign matter. The filter 143 can include, by way of non-limiting example, a chemical filtering media. Optionally, a heater 144 can be provided to regulate the temperature of the electrolytic solution 148 in the bath tank 145. In non-limiting examples, the heater 144 can be disposed within the bath tank 145 or proximate the bath tank 145 exterior to the bath tank 145. Alternatively, the heater 144 can be in fluid communication with the fluid pump 147 to heat the electrolytic solution 148 as the electrolytic solution 148 is pumped by the fluid pump 147.

[0056] The electrical power supply 190, which can include a controller (not shown), can be electrically coupled to the anode 160 and the cathode 180 by electrical conduits 191 to form a circuit 192 via the electrolytic solution 148. The electrical power supply 190 can operatively create an electric field 193 across the electrolytic solution 148 between the anode 160 and cathode 180. Optionally, a switch (not shown) or sub-controller can be included along the electrical conduits 191, and can be positioned between the electrical power supply 190 and the anode 160 and cathode 180. The electrical power supply 190 can be configured to provide an electrical current 195 (illustrated as dashed arrows) to the anode 160 (e.g. a plating current) which can flow through the electrolytic solution 148 from the anode 160 to the cathode 180. The electrical current 195 can cause metal ions to move from the anode 160 to the cathode 180 and deposit thereon.

[0057] FIG. 2B depicts a cross-section of the system 110 taken along the line II-II of FIG. 2A, with some parts omitted for clarity. The injection manifold 150 can at least one wall 150a arranged to define a manifold interior 158. The at least one wall 150a can further define the set of injection nozzles 159 therethrough. As such, the manifold interior 158 defines a passageway for the electrolytic fluid flow 149, in fluid communication with the set of injection nozzles 159. The injection manifold 150 is coupled in fluid communication to the fluid inlet duct 141 (FIG. 2A) to receive the electrolytic fluid flow 149 therefrom. In this way, the electrolytic fluid flow 149 can be arranged to flow, from upstream to downstream, from the fluid inlet duct 141 to the injection manifold 150, then radially outward through the set of injection nozzles 159 into the bath tank 145 toward the anode 160.

[0058] The anode 160 can be a sacrificial anode or an inert anode. While one anode 160 is shown, it should be understood that the bath tank 145 can include any number of anodes 160 as desired. The anode 160 can be arranged to define a container, or anode basket 165. The anodic material 160a can be supported by, or housed within, the anode basket 165. In some aspects, the anodic material 160a can be in the form of, without limitation, a set of spheres, pellets, discs, cubes, flakes, or any other desired geometric shape including amorphous.

[0059] The anode basket 165 can be formed of an electrically conductive metal (e.g., titanium) that is not soluble in the electrolytic solution 148 and is capable of holding a positive voltage potential to allow metal ions to be liberated from the anodic material 160a contained therein. In non-limiting aspects, the anode basket 165 can include a set of walls 164 arranged to define a basket interior 167 therebetween. For example, each wall 164 can have a first inward-facing surface 164a facing the basket interior 167, and an opposing outward-facing surface 164b facing an exterior of the anode basket 165. The anode basket 165 can also include a floor or bottom 166. The bottom 166 can define a set of first apertures 166a therethrough, arranged to allow an ingress of the electrolytic fluid flow 149 therethrough from the exterior of the anode basket 165 to the basket interior 167 and through or past the anodic material 160a. In some aspects, the bottom 166 can further provide or define a support surface for the anodic material 160a. The first apertures 166a can be smaller than anodic material 160a to prevent ingress of the anodic material 160a into the first apertures 166a. While the first apertures 166a are illustrated in the example of FIG. 2B as being generally cylindrical, and having substantially the same size and orientation as each other, other aspects are not so limited. It is contemplated that in other aspects the size, shape, and relative orientation of the first apertures 166a can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic, including for example, velocity and direction of the electrolytic fluid flow 149, without departing from the scope of the disclosure.

[0060] In non-limiting aspects, the anode basket 165 can also include a ceiling or cover 169. The cover 169 can define a set of second apertures 169a therethrough, arranged to allow an egress of the electrolytic fluid flow 149 therethrough from the basket interior 167 to the exterior of the anode basket 165. While the second apertures 169a are illustrated in the example of FIG. 2B as being generally cylindrical, and having substantially the same size and orientation as each other, other aspects are not so limited. It is contemplated that in other aspects, the size, shape, and relative orientation of the second apertures 169a can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic including, for example, a velocity and a direction of the electrolytic fluid flow 149, without departing from the scope of the disclosure. It is further contemplated that in other aspects, the cover 169 can be omitted, such that the anode basket 165 has an open top. In some aspects, one or more of the walls 164 can define a respective set of third apertures 164c therethrough to allow ingress or egress, or both, of the electrolytic solution 148.

[0061] The cathode shield 170 is disposed in the bath tank 145 between the anode 160 and the cathode 180. The cathode shield 170 can define a cathode shield body 171. In non-limiting aspects, the cathode shield body 171 can define a set of cathode shield apertures 176 therethrough. The cathode shield apertures 176 can be sized and oriented to receive the electrolytic fluid flow 149 therethrough. It is contemplated that in various aspects, the cathode shield 170 can define any desired number of cathode shield apertures 176. The cathode shield apertures 176 can be axially spaced from each other along a length of the cathode shield 170. For example, in non-limiting aspects the cathode shield apertures 176 can be spaced apart in a row along an axial length of the cathode shield 170. At least a subset of the set of cathode shield apertures 176 can be aligned (e.g., with respect to a direction of the electrolytic fluid flow 149) with the cathode 180. The set of cathode shield apertures 176 can be sized and arranged to control, direct or guide a velocity, or a direction, or both, of the electrolytic fluid flow 149.

[0062] The cathode shield 170 can be formed of an electrically non-conductive or ionically resistive material. In non-limiting aspects, the cathode shield 170 can be formed of a dielectric material including, but not limited to polymers, glasses, and ceramics. For example, the cathode shield 170 can be made of polyethylene, polypropylene, fluoropolymers (e.g., Teflon® or PVDF), and the like.

[0063] In non-limiting aspects, the cathode 180 can include a mandrel 182. The mandrel 182 can include an exterior metallic layer 183 (e.g., an outer coating). For example, in non-limiting aspects, the exterior metallic layer 183 can be formed of, without limitation, copper, silver, or nickel. It is contemplated that the exterior metallic layer 183 can be formed on the mandrel 182 via a spray, painting, coating, or similar treatment to facilitate formation of the cathode 180.

[0064] The mandrel 182 can be formed (e.g., by molding, machining, additive manufacturing, etc.) in a shape corresponding to a desired shape of metallic component 138. The mandrel 182 includes a mandrel body 185 formed from, by way of non-limiting example, a reclaimable material. For example, the mandrel body 185 can be made of a reclaimable material that can be collected after an electroforming process and reused as another body in another electroforming process. Suitable reclaimable materials can include waxes, plastics, polymer foams, metals, or deformable materials, such as those materials that are collectible via melting or leaching in non-limiting examples. After completion of the electroforming process, the mandrel body 185 can be reclaimed from the electroformed component, such as through heating and melting of the mandrel body 185 at heightened temperatures, to reclaim the structural material.

[0065] In operation, the bath tank 145 can contain a suitable amount or level of the electrolytic solution 148, sufficient to cover or immerse the injection manifold 150, anode basket 165, and cathode 180. The fluid pump 147 can operate to circulate the electrolytic solution 148 through the bath tank 145 from the fluid inlet duct 141 to the fluid outlet duct 142. The electrolytic solution 148 flows into the injection manifold 150 and is injected from the set of injection nozzles 159 toward the anode 160 to define the electrolytic fluid flow 149. The electrolytic fluid flow 149 can flow through the first apertures 166a, and through gaps or spaces defined between and around the anode material 160a contained in the anode basket 165. In non-limiting aspects, the electrolytic fluid flow 149 can then flow from the anode 160 toward the cathode shield 170. The cathode shield 170 can partially block, impede, or redirect a portion of the electrolytic fluid flow 149, while allowing another portion of the electrolytic fluid flow 149 to flow around the cathode shield body 171, and / or through the set of cathode shield apertures 176 defined therethrough to flow toward the cathode 180.

[0066] The electrical power supply 190, can operatively create the electric field 193 across the electrolytic solution 148 between the anode 160 and cathode 180. The electric field 193 can cause the electrical current 195 to flow through the electrolytic solution 148 from the anode 160 to the cathode 180. The electrical current 195 can cause metal ions from the anode material 160a (e.g., tungsten) to move from the anode 160 to the cathode 180 and deposit onto the mandrel 182 to form the metallic component 138. In a non-limiting example, the metallic component 138 can be a fan blade shield 37.

[0067] An electrodeposition rate of the anode material 160a at a particular region of the cathode 180 will depend in part on a variety of factors, including characteristics of the electrolytic solution fluid flow 149, the electric field 193, the electrical current 195 through the electrolytic solution 148 between the anode 160 and the cathode 180, and the characteristics of the electrolytic fluid flow 149 at any given point or region on the cathode 180. For example, in non-limiting aspects, a thickness profile of the electrodeposited metal ions on the mandrel 182 can be selectively controlled at least in part by configuring the size, shape, orientation, and combinations thereof, of the cathode shield 170 and cathode shield apertures 176, to modulate the electric field 193 or guide the electrolytic fluid flow 149, or both, or a combination thereof.

[0068] The cathode shield 170 can be arranged and disposed to mask predetermined points or portions of the surface of the cathode 180 from the electrical current 195 and / or the electrolytic fluid flow 149. For example, since the cathode shield 170 is electrically non-conductive (e.g., formed of a dielectric material) an intensity of the electric field 193, between the anode 160 and each given point on the cathode 180 can be selectively varied or modulated by the presence of the cathode shield 170. Furthermore, the shape, size, and location of the cathode shield body 171 within the electrolytic fluid flow 149, as well as the size, quantity, and location of the cathode shield apertures 176 can affect the characteristics (e.g., velocity and direction) of the electrolytic fluid flow 149 with respect to the cathode 180.

[0069] It is expected that exterior regions of the cathode 180 having an unmasked (e.g., not masked by the cathode shield 170) surface area will experience a relatively higher charge transfer rate than exterior regions of the cathode 180 having a masked (e.g., by the cathode shield 170) surface area. Therefore, the electrodeposition rate (and thus the thickness profile of the electrodeposited metal) can be controlled by appropriately shaping the cathode shield 170 and configuring the cathode shield apertures 176 to arrange a desired characteristic (e.g., velocity and direction) of the electrolytic fluid flow 149.

[0070] Additionally, or alternatively, in non-limiting aspects, the characteristics of the electrolytic fluid flow 149 can be controlled by adjusting the velocity of the electrolytic fluid flow 149, or the direction of the electrolytic fluid flow 149, or both. For example, in non-limiting aspects, the fluid pump 147 can be configured to increase or decrease the velocity of the electrolytic fluid flow 149 in the fluid inlet duct 141, or injection manifold 150, or both. In some non-limiting aspects, the velocity of the electrolytic fluid flow 149 or the direction of the electrolytic fluid flow 149, or both, through the bath tank 145 can be further controlled by configuring the set of injection nozzles 159 as desired.

[0071] Of course, the actual thickness profile of the electrodeposited metal will additionally depend on the various parameters used in the electroplating process (e.g., the metal used, the voltage and current applied, the concentration, temperature, flow and type of the additives and components in the bath tank 145).

[0072] FIG. 3 illustrates a method 300 for forming the metallic component 138. The method 300 is provided for illustrative purposes and may proceed in a different logical order or additional or intervening steps may be included, unless otherwise noted. While the method 300 is described in the context of the system 110 depicted in FIGS. 2A-2B, for forming the metallic component 138 by electrodeposition onto a mandrel 182, the method 300 may be used in a similar manner to form other types of bodies using other suitable forms.

[0073] The method 300 begins at 310 with disposing an electrolytic solution 148 into a bath tank 145 having a fluid inlet duct 141 and a fluid outlet duct 142, the fluid inlet duct 141 and the fluid outlet duct 142 fluidly coupled with the electrolytic solution 148.

[0074] In non-limiting aspects, the electrolytic solution 148 can include aluminum alloy carrying alloying metal ions. In another non-limiting example, the electrolytic solution 148 can include a nickel alloy carrying alloying metal ions. In non-limiting aspects, the bath tank 145 can be fabricated from suitably acid-resistant material such as polyethylene, polypropylene, fluoropolymers (e.g., Teflon® or PVDF).

[0075] The method 300 can include, at 315, immersing an injection manifold 150 including the set of injection nozzles 159 in the electrolytic solution 148 in the bath tank 145. In non-limiting aspects, the injection manifold 150 can include a body having at least one wall 150a arranged to define a manifold interior 158. The at least one wall 150a can further define the set of openings or injection nozzles 159 therethrough. In non-limiting aspects, the manifold interior 158 can define a passageway for an electrolytic solution fluid flow 149, in fluid communication with the set of injection nozzles 159.

[0076] The method 300 can include, at 320, fluidly coupling the injection manifold 150 to the fluid inlet duct 141, and at 325, coupling a fluid pump 147 in fluid communication to the fluid outlet duct 142 to receive the electrolytic solution 148 therefrom.

[0077] The method 300 can further include, at 330, coupling the fluid pump 147 in fluid communication to the fluid inlet duct 141 to provide the electrolytic solution 148 thereto. In some non-limiting aspects, a filter 143 can optionally be provided to filter and chemically maintain the electrolytic solution 148 at a particular ion concentration, or to remove any foreign matter. The filter 143 can include, by way of non-limiting example, a chemical filtering media. Optionally, a heater 144 can be provided to regulate a temperature of the electrolytic solution 148 in the bath tank 145. In non-limiting examples, the heater 144 can be disposed within the bath tank 145 or proximate the bath tank 145 exterior to the bath tank 145. Alternatively, the heater 144 can be in fluid communication with the fluid pump 147 to heat the electrolytic solution 148 as it is pumped by the fluid pump 147.

[0078] The method 300 can include, at 335, fluidly pumping the electrolytic solution 148 from the fluid inlet duct 141 to the injection manifold 150. The method 300 can further include, at 340, injecting the electrolytic solution 148 from the injection manifold 150 into the bath tank 145 to define an electrolytic fluid flow 149 within the bath tank 145, the electrolytic fluid flow 149 extending from the injection manifold 150 to the fluid outlet duct 142. In non-limiting aspects, the electrolytic fluid flow 149 can be arranged to flow, from upstream to downstream, from the fluid inlet duct 141 to the injection manifold 150, then radially outward through the set of injection nozzles 159 into the bath tank 145 toward an anode 160. For example, in non-limiting aspects, the fluid inlet duct 141 and the fluid outlet duct 142 can be arranged or oriented with respect to each other in a variety of ways as desired to enable the electrolytic fluid flow 149 to flow, from upstream to downstream, from the fluid inlet duct 141, to the injection manifold 150, to the anode 160, to a cathode 180, and to the fluid outlet duct 142.

[0079] The method 300 can include, at 345, disposing the anode 160 in the bath tank 145 downstream of the injection manifold 150. The anode 160 can be a sacrificial anode or an inert anode. The anode 160 can include an anodic material 160a. In some exemplary aspects, the anodic material 160a can be in the form of, without limitation, a set of spheres, pellets, discs, cubes, flakes, or any other desired geometric shape including amorphous.

[0080] In non-limiting aspects, the anodic material 160a can be disposed in an anode basket 165. The anode basket 165 can be formed of an electrically conductive metal (e.g., titanium) that is not soluble in the electrolytic solution 148 and is capable of holding a positive voltage potential and allowing metal ions to be liberated from the anodic material 160a contained therein. In non-limiting aspects, the anode basket 165 can include a body having a set of walls 164 arranged to define a basket interior 167 therebetween. For example, each wall 164 can have a first inward-facing surface 164a facing the basket interior 167, and an opposing send outward-facing surface 164b facing an exterior of the anode basket 165. The anode basket 165 can also include a floor or bottom 166. The bottom 166 can define a set of first apertures 166a therethrough, arranged to allow an ingress of the electrolytic fluid flow 149 therethrough from the exterior of the anode basket 165 to the basket interior 167 and through or past the anodic material 160a. In some aspects, the bottom 166 can further provide or define a support surface for the anodic material 160a. The first apertures 166a can be smaller than anodic material 160a to prevent ingress of the anodic material 160a into the first apertures 166a. In non-limiting aspects, the size, shape, and relative orientation of the first apertures 166a can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic, including velocity and direction of the electrolytic fluid flow 149.

[0081] In non-limiting aspects, the anode basket 165 can also include a ceiling or cover 169. The cover 169 can define a set of second apertures 169a therethrough, arranged to allow an egress of the electrolytic fluid flow 149 therethrough from the basket interior 167 to the exterior of the anode basket 165. In non-limiting aspects, the size, shape, and relative orientation of the second apertures 169a can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic including a velocity and a direction of the electrolytic fluid flow 149, without departing from the scope of the disclosure. In other aspects, the cover 169 can be omitted, such that the anode basket has an open top. In some aspects, one or more of the walls 164 can define a respective set of third apertures 164c therethrough to allow ingress or egress or both of the electrolytic solution 148.

[0082] The method 300 can include, at 350, disposing a cathode 180 in the bath tank 145 downstream of the anode 160. In non-limiting aspects, the cathode 180 can be a mandrel 182 having exterior metallic layer 183 (e.g., an exterior coating. For example, in non-limiting aspects, the exterior metallic layer 183 can be formed of, without limitation, copper, silver, or nickel. In non-limiting aspects, the exterior metallic layer 183 can be applied to the mandrel 182 via a spray, painting, coating, or similar treatment to facilitate formation of the cathode 180.

[0083] The mandrel 182 can include a mandrel body 185 formed from, by way of non-limiting example, a reclaimable material. For example, the mandrel body 185 can be made of a reclaimable material that can be collected after an electroforming process and reused as another body in another electroforming process. Suitable reclaimable materials can include waxes, plastics, polymer foams, metals, or deformable materials, such as those materials that are collectible via melting or leaching in non-limiting examples. After completion of the electroforming process, the mandrel body 185 can be reclaimed from the electroformed component, such as through heating and melting of the mandrel body 185 at heightened temperatures, to reclaim the structural material. The mandrel 182 can define or correspond to the shape of the metallic component 138.

[0084] The method 300 can include, at 355, electrically coupling the electrical power supply 190 to the anode 160 and the cathode 180 to provide an electrical current 195 therebetween through the electrolytic solution 148. The electrical power supply 190, can be electrically coupled to the anode 160 and the cathode 180 by electrical conduits 191 to form a circuit 192 via the electrolytic solution 148. The electrical power supply 190 can operatively create an electric field 193 across the electrolytic solution 148 between the anode 160 and the cathode 180. The electrical current 195 can cause metal ions to move from the anode 160 to the cathode 180 and deposit onto the mandrel 182.

[0085] In non-limiting aspects, the method 300 can optionally include, at 360, disposing a cathode shield 170 in the bath tank 145 between the anode 160 and the cathode 180. The cathode shield 170 can be formed of an electrically non-conductive or ionically resistive material. In non-limiting aspects, the cathode shield 170 can be formed of a dielectric material including, but not limited to polymers, glasses, and ceramics. For example, the cathode shield 170 can be made of polyethylene, polypropylene, fluoropolymers (e.g., Teflon® or PVDF), and the like.

[0086] In non-limiting aspects, the cathode shield 170 includes a cathode shield body 171 defining a set of cathode shield apertures 176 therethrough. The cathode shield apertures 176 can be sized and oriented to receive the electrolytic fluid flow 149 therethrough. The cathode shield apertures 176 can be axially spaced from each other along a length of the cathode shield 170. At least a subset of the set of cathode shield apertures 176 can be aligned (e.g., with respect to a direction of the electrolytic fluid flow 149) with the cathode 180. The set of cathode shield apertures 176 can be sized and arranged to control, direct or guide a velocity, or a direction, or both, of the electrolytic fluid flow 149.

[0087] Advantageously, the method 300 described herein allows improved control of the thickness of the electroformed metallic component over conventional techniques. Furthermore, the method 300 provides for generating a metallic component that has a decreased porosity over conventional methods. The decreased porosity afforded by the method 300 can enhance aerodynamic performance of the metallic component when used as a fan blade shield 37. Additionally, the system 110 and method 300 as disclosed herein can reduce anode bridging without need of a mechanical agitator. Overall, this manufacturing process simplification reduces time, cost, and defects, and can provide for an overall improvement in the final product, such as increased smoothness, reduced porosity, or controlled thickness, and combinations thereof, as compared with that of a similar metallic component formed by a different method. Additionally, the system 110 and method 300 as disclosed herein enables improved thickness control and profile control over conventional systems and methods for example by providing a controlled flow of electrons and a controlled electrolytic solution fluid flow.

[0088] To the extent not already described, the different features and structures of the various aspects can be used in combination with each other as desired. That one feature cannot be illustrated in all of the aspects is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different aspects can be mixed and matched as desired to form new examples, whether or not the new examples are expressly described. Combinations or permutations of features described herein are covered by this disclosure. Many other possible aspects and configurations in addition to that shown in the above figures are contemplated by the present disclosure.

[0089] This written description uses examples to describe aspects of the disclosure described herein, including the best mode, and also to enable any person skilled in the art to practice aspects of the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of aspects of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

[0090] Further aspects of the disclosure are provided by the subject matter of the following clauses:

[0091] A system for electroforming a metallic component, comprising: a bath tank configured to hold an electrolytic solution, the bath tank having a fluid inlet duct and a fluid outlet duct, the fluid inlet duct and the fluid outlet duct fluidly coupled with the electrolytic solution; a fluid pump coupled in fluid communication to the fluid inlet duct to provide the electrolytic solution thereto, and coupled in fluid communication to the fluid outlet duct to receive the electrolytic solution therefrom; an injection manifold coupled in fluid communication to the fluid inlet duct to receive the electrolytic solution therefrom, the injection manifold including a set of injection nozzles configured to inject the electrolytic solution therefrom into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow extending from the injection manifold to the fluid outlet duct; an anode disposed in the bath tank downstream of the injection manifold with respect to the electrolytic solution fluid flow; a cathode disposed in the bath tank downstream of the anode with respect to the electrolytic solution fluid flow; and an electrical power supply electrically coupled to the anode and the cathode to provide an electrical current therebetween through the electrolytic solution in the bath tank.

[0092] The system of any preceding clause, wherein the injection nozzles are axially spaced from each other along a length of the injection manifold.

[0093] The system of any preceding clause, wherein the anode includes an anode basket, configured to support an anodic material, the anode basket defining a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

[0094] The system of any preceding clause, wherein the anode basket is formed from an electrically conductive material.

[0095] The system of any preceding clause, further comprising a cathode shield, including a cathode shield body formed of a dielectric material, the cathode shield disposed in the bath tank between the anode and the cathode, in fluid communication with the electrolytic solution fluid flow.

[0096] The system of any preceding clause, wherein the cathode shield includes a set of cathode shield apertures defined therethrough, the cathode shield apertures configured to receive the electrolytic solution fluid flow therethrough.

[0097] The system of any preceding clause, wherein the cathode includes a mandrel.

[0098] The system of any preceding clause, wherein the mandrel is formed with a reclaimable material.

[0099] The system of any preceding clause, wherein the mandrel includes an exterior metallic layer.

[0100] The system of any preceding clause, wherein the bath tank includes a heater configured to heat the electrolytic solution.

[0101] The system of any preceding clause, wherein the metallic component is a fan blade shield for a fan blade.

[0102] A method of electroforming a metallic component, the method comprising: disposing an electrolytic solution into a bath tank having a fluid inlet duct and a fluid outlet duct, the fluid inlet duct and the fluid outlet duct fluidly coupled with the electrolytic solution; immersing an injection manifold including a set of injection nozzles in the electrolytic solution in the bath tank; coupling the injection manifold in fluid communication with the fluid inlet duct; coupling a fluid pump in fluid communication with the fluid outlet duct to receive the electrolytic solution therefrom; coupling the fluid pump in fluid communication with the fluid inlet duct to provide the electrolytic solution thereto; pumping the electrolytic solution from the fluid inlet duct to the injection manifold; injecting the electrolytic solution from the injection manifold into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow extending from the injection manifold to the fluid outlet duct; disposing an anode in the bath tank downstream of the injection manifold with respect to the electrolytic solution fluid flow; disposing a cathode in the bath tank downstream of the anode with respect to the electrolytic solution fluid flow; and electrically coupling a power supply to the anode and the cathode to provide an electrical current therebetween through the electrolytic solution.

[0103] The method of any preceding clause, wherein the injection nozzles are axially spaced from each other along a length of the injection manifold.

[0104] The method of any preceding clause, wherein the anode includes an anode basket configured to support an anodic material, the anode basket defining a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

[0105] The method of any preceding clause, wherein the anode basket is formed from an electrically conductive material.

[0106] The method of any preceding clause, further comprising disposing a cathode shield having a cathode shield body formed of a dielectric material in the bath tank between the anode and the cathode, in fluid communication with the electrolytic solution fluid flow.

[0107] The method of any preceding clause, wherein the cathode shield includes a set of cathode shield apertures defined therethrough, the cathode shield apertures configured to receive the electrolytic solution fluid flow therethrough.

[0108] The method of any preceding clause, wherein the cathode includes a mandrel formed with a reclaimable material.

[0109] The method of any preceding clause, wherein the bath tank includes a heater configured to heat the electrolytic solution.

[0110] The method of any preceding clause, wherein the metallic component is a shield for a fan blade.

Examples

Embodiment Construction

[0009]The present disclosure relates to a method and system for forming a metallic component. More specifically, the disclosure relates to a method and system for electroforming a metallic component which provides improved wall thickness control with reduced porosity and pitting of the metallic component over conventional methods and systems.

[0010]For purposes of illustration, the aspects of the disclosure discussed herein will be described in terms of a fan blade shield for a gas turbine engine fan blade. It will be understood, however, that the disclosure as discussed herein is not so limited and may have general applicability to electroforming any desired metallic component, used in any desired application including non-aircraft applications, such as other mobile applications and non-mobile industrial, commercial, and residential applications without departing from the scope of the disclosure.

[0011]Reference will now be made in detail to various aspects, one or more examples of w...

Claims

1. A system for electroforming a metallic component, comprising:a bath tank configured to hold an electrolytic solution, the bath tank having a fluid inlet duct and a fluid outlet duct, the fluid inlet duct and the fluid outlet duct fluidly coupled with the electrolytic solution;a fluid pump coupled in fluid communication to the fluid inlet duct to provide the electrolytic solution thereto, and coupled in fluid communication to the fluid outlet duct to receive the electrolytic solution therefrom;an injection manifold coupled in fluid communication to the fluid inlet duct to receive the electrolytic solution therefrom, the injection manifold including a set of injection nozzles configured to inject the electrolytic solution therefrom into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow extending from the injection manifold to the fluid outlet duct;an anode disposed in the bath tank downstream of the injection manifold with respect to the electrolytic solution fluid flow;a cathode disposed in the bath tank downstream of the anode with respect to the electrolytic solution fluid flow; andan electrical power supply electrically coupled to the anode and the cathode to provide an electrical current therebetween through the electrolytic solution in the bath tank.

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

3. The system of claim 1, wherein the anode includes an anode basket, configured to support an anodic material, the anode basket defining a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

4. The system of claim 3, wherein the anode basket is formed from an electrically conductive material.

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

6. The system of claim 5, wherein the cathode shield includes a set of cathode shield apertures defined therethrough, the cathode shield apertures configured to receive the electrolytic solution fluid flow therethrough.

7. The system of claim 1, wherein the cathode includes a mandrel.

8. The system of claim 7, wherein the mandrel is formed with a reclaimable material.

9. The system of claim 8, wherein the mandrel includes an exterior metallic layer.

10. The system of claim 1, wherein the bath tank includes a heater configured to heat the electrolytic solution.

11. The system of claim 1, wherein the metallic component is a fan blade shield for a fan blade.

12. A method of electroforming a metallic component, the method comprising:disposing an electrolytic solution into a bath tank having a fluid inlet duct and a fluid outlet duct, the fluid inlet duct and the fluid outlet duct fluidly coupled with the electrolytic solution;immersing an injection manifold including a set of injection nozzles in the electrolytic solution in the bath tank;coupling the injection manifold in fluid communication with the fluid inlet duct;coupling a fluid pump in fluid communication with the fluid outlet duct to receive the electrolytic solution therefrom;coupling the fluid pump in fluid communication with the fluid inlet duct to provide the electrolytic solution thereto;pumping the electrolytic solution from the fluid inlet duct to the injection manifold;injecting the electrolytic solution from the injection manifold into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow extending from the injection manifold to the fluid outlet duct;disposing an anode in the bath tank downstream of the injection manifold with respect to the electrolytic solution fluid flow;disposing a cathode in the bath tank downstream of the anode with respect to the electrolytic solution fluid flow; andelectrically coupling a power supply to the anode and the cathode to provide an electrical current therebetween through the electrolytic solution.

13. The method of claim 12, wherein the injection nozzles are axially spaced from each other along a length of the injection manifold.

14. The method of claim 12, wherein the anode includes an anode basket configured to support an anodic material, the anode basket defining a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

15. The method of claim 14, wherein the anode basket is formed from an electrically conductive material.

16. The method of claim 12, further comprising disposing a cathode shield having a cathode shield body formed of a dielectric material in the bath tank between the anode and the cathode, in fluid communication with the electrolytic solution fluid flow.

17. The method of claim 16, wherein the cathode shield includes a set of cathode shield apertures defined therethrough, the cathode shield apertures configured to receive the electrolytic solution fluid flow therethrough.

18. The method of claim 12, wherein the cathode includes a mandrel formed with a reclaimable material.

19. The method of claim 12, wherein the bath tank includes a heater configured to heat the electrolytic solution.

20. The method of claim 12, wherein the metallic component is a shield for a fan blade.

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