System and method for electroforming a metallic component

Abstract

A system for electroforming a metallic component includes an anode spaced from a cathode in an electrolytic solution. The system can include a gas injection manifold for injecting a gas into the electrolytic solution within the bath tank to define a gaseous flow. The system can further include an electrolytic solution injection manifold for injecting an electrolytic solution through set of fluid injection nozzles into the bath tank to define an electrolytic solution fluid flow. A cathode shield can be disposed between the anode and the cathode.

Description

TECHNICAL FIELD

[0001] The disclosure generally relates to metallic components and, more particularly, relates to a system 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 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 schematic illustration of a system for forming a metallic component according to another exemplary aspect of the present disclosure.

[0009] FIG. 4 is a schematic illustration of a portion of a system for forming a metallic component according to yet another exemplary aspect of the present disclosure.

[0010] FIG. 5 is a schematic illustration of a system for forming a metallic component according to still another exemplary aspect of the present disclosure.

[0011] FIG. 6 is a flow diagram illustrating a method of electroforming a metallic component according to an exemplary aspect of the present disclosure.DETAILED DESCRIPTION

[0012] 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, and reduced cross anode and cathode interactions over conventional methods and systems.

[0013] 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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, anodic material, cathode material, electrolytic solution properties such as an ion concentration, conductivity, resistivity, temperature, viscosity, pH level, chemical stability, additives, impurities, and the like.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] Additionally, strikes by relatively smaller foreign objects (e.g., sand) can progressively erode the blade material resulting in degraded performance of the fan and engine.

[0029] 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 the fan blade leading edge. The fan blade shields also allow the energy of the impact to be transmitted through the fan blade shield over a larger area than the impact position.

[0030] 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.

[0031] Titanium and alloys thereof provide high strength to weight ratios, good temperature and chemical resistance, and relatively 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.

[0032] 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.

[0033] 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 anodic material is dissolved by electrochemical action to continuously replenish the metallic content of the electrolyte which is consumed as a result of plating or forming on the article. The anodic 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.

[0034] 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 anodic material. The anodic material can be formed as relatively small pieces (sometimes referred to as fines, coins, pellets, 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 anodic material contained therein through openings provided in the anode basket. In operation, the anodic material can be gradually consumed and replaced as necessary at appropriate intervals.

[0035] 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, it is removed. The electro-deposited 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.

[0036] 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.

[0037] One problem with conventional techniques for electroforming metallic components is that, since the material deposition speed is directly proportional to current density, any non-uniformity of the distribution of the current density between the anode and the cathode can require more time to achieve a desired thickness of the deposited material, resulting in a time consuming and costly process. Portions of the cathode which are closer to the anode (e.g., protruding areas) are exposed to a higher current density so more metal is plated onto the protruding areas of the cathode than onto the portions of the cathode farther from the anode (e.g., recessed areas). A faster deposition in protruding areas consequently increases the current density and thus increases the deposition rate in the protruding areas, and likewise reduces the deposition rate in the recessed areas. Such uneven distribution of current density results in not only uneven distribution of the deposited material but can also lead to dendrite or like crystalline formations forming on the cathode. Typically, to reduce the formation of crystalline formations, a conventional electroforming process is often conducted at a minimum current density thus requiring extensive time for an electroformed metal layer to reach a desired thickness. However, even at a low current density uneven material deposition can still occur. In some cases, the electroforming process can be interrupted, and the object removed from the electrolytic solution, to perform an additional step of cutting or removing dendrite and part of the metal deposited at the protruding areas to reduce the increasing current density at these areas. Electroforming at a higher current density accelerates the deposition rate, but worsens the non-uniformity and increases the rate of dendrite buildup.

[0038] Another problem in conventional electroforming operations, is that as the individual pieces of anodic material gradually decrease in size over time, voids are created in the anodic material due to bridging of individual anode pieces. Such bridging prevents the anodic material from settling to the bottom of the anode basket as it is consumed, and thus prevents the formation of sufficient room for the addition of new anodic material to the anode basket. The bridging also results in a variable quantity of anodic material in contact with the electrolyte over time resulting in poor uniformity of the deposited material and increased porosity on the electro-formed surface.

[0039] 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 anodic 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 anodic material. Such techniques and / or mechanisms can add additional costs, and in some cases can result in damage the basket.

[0040] Yet another problem associated with conventional electroforming techniques is an inherent formation of gas bubbles (e.g., hydrogen) on a surface of the cathode during electroforming. Such bubbles can result in undesired pitting or porosity on a surface of the electroformed component.

[0041] 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 of electroforming fan blade shields, with improved operational efficiency and reasonable cost.

[0042] For example, aspects as disclosed herein can provide a gas injection manifold to operatively inject a gaseous flow into the electrolytic solution during electroforming operations, which can agitate, dislodge, or otherwise remove the gas bubbles formed on the cathode surface. Furthermore, when arranged upstream of the anode, the gas injection manifold can additionally inject the gaseous flow into the electrolytic solution during electroforming operations, to agitate the anode basket to settle the anodic material to thereby reduce bridging of the anodic material without need of a mechanical agitator.

[0043] Aspects as disclosed herein can additionally 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. The electrolytic fluid flow can enable a controlled flow of ions through the electrolytic solution, to 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.

[0044] Systems and methods disclosed herein provide for generating a metallic component that has a decreased porosity and pitting of the metallic component over conventional methods. The decreased porosity and pitting afforded by the aspects disclosed herein can enhance aerodynamic performance of the metallic component when used as a fan blade shield.

[0045] Non-limiting aspects as disclosed herein can also provide a conforming anode, having a shape that conforms to a shape of the cathode to provide an even distribution of current density and a consequent even distribution of the deposited material Additionally, aspects disclosed herein can include a cathode shield placed between the anode and cathode to influence or direct the electrical current through the electrolytic solution from the anode and the cathode, to further arrange an even flow of ions through the electrolytic solution, resulting in an even deposition of anodic material onto the cathode.

[0046] 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 a LP turbine 36, and an exhaust section 38.

[0047] 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.

[0048] 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 the 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] FIG. 2A depicts a schematic illustration of non-limiting aspect of a system 110 for electroforming 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 143. The system 110 can further include an electrolytic solution injection manifold 150 defining a set of openings or fluid injection nozzles 159. An anode 160, a cathode 180, and the electrolytic solution injection manifold 150 can be submerged or disposed in the electrolytic solution 148. The anode 160 is spaced from the cathode 180. The anode 160 is disposed between the electrolytic solution injection manifold 150 and the cathode 180. Any number of mechanical brackets or hangers 145a can be used to position the electrolytic solution injection manifold 150, the anode 160, and the cathode 180 in the bath tank 145 as desired. The system 110 can further include a fluid pump 147. A power supply 190 (e.g., a DC electrical power supply) can be disposed outside of the bath tank 145 and electrically coupled to the anode 160 and the cathode 180.

[0061] 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)).

[0062] The fluid pump 147 is coupled in fluid communication with the fluid inlet duct 141 and the fluid outlet duct 143 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 electrolytic solution injection manifold 150 to provide the electrolytic solution 148 thereto. The fluid outlet duct 143 is arranged in fluid communication with the electrolytic solution 148 disposed in the bath tank 145 to receive the electrolytic fluid flow 149 therefrom.

[0063] 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 143 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 143 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 143 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 electrolytic solution injection manifold 150, to the anode 160, to the cathode 180, and to the fluid outlet duct 143.

[0064] 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 143. In some non-limiting aspects, a filter 144 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 144 can include, by way of non-limiting example, a chemical filtering media. Optionally, a heater 146 can be provided to regulate the temperature of the electrolytic solution 148 in the bath tank 145. In non-limiting examples, the heater 146 can be disposed within the bath tank 145 or proximate the bath tank 145 exterior to the bath tank 145. Alternatively, the heater 146 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.

[0065] The 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 power supply 190 can operatively creates 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 power supply 190 and the anode 160 and cathode 180. The 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 (not shown) to move from the anode 160 to the cathode 180 and deposit thereon.

[0066] A surface geometry of the cathode 180 can be based on or conform to a desired geometry of the metallic component 138 to be electroformed. In non-limiting aspects, the cathode 180 can include a mandrel 182 having a mandrel body 185. The mandrel body 185 can have an exterior mandrel surface 185a. The mandrel surface 185a is shaped and arranged to conform to the desired shape of the metallic component 138 to be electroformed. The exterior mandrel surface 185a can be formed of an electrically conductive material (e.g., a coating). For example, in non-limiting aspects, the electrically conductive material can be, without limitation, copper, silver, or nickel. It is contemplated that the electrically conductive material can be applied to the mandrel body 185 via a spray, painting, coating, or similar treatment to facilitate formation of the cathode 180.

[0067] The mandrel body 185 can be 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.

[0068] In non-limiting aspects, the anode 160 can be a conforming anode. For example, the anode 160 can have a surface geometry that conforms to or complements a surface geometry of cathode 180 (e.g., the exterior mandrel surface 185a) or a surface geometry of the metallic component 138 to be formed. In other aspects, the anode 160 can be a non-conforming anode

[0069] 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. As illustrated, the electrolytic solution injection manifold 150 can include at least one wall 150a arranged to define a manifold interior 158. The at least one wall 150a can further define the set of fluid 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 fluid injection nozzles 159. The electrolytic solution injection manifold 150 is coupled in fluid communication to the first 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 electrolytic solution injection manifold 150, then radially outward through the set of fluid injection nozzles 159 into the bath tank toward the anode 160.

[0070] 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. 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. In non-limiting aspects, the anode 160 can include a container or anode basket 165 arranged to hold or support the anodic material 160a. The anodic material 160a can be disposed in, or on, the anode basket 165. In such aspects, the anode basket 165 can have a surface geometry that matches or complements the cathode 180 or the metallic component 138 to be formed.

[0071] 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 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 second outward-facing surface 164b facing an exterior of the anode basket 165.

[0072] The anode basket 165 also includes 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 166b for the anodic material 160a. In non-limiting aspects, support surface 166b can have a surface geometry that matches or conforms to a surface geometry of the cathode 180 or the metallic component 138 to be formed. 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, a velocity and a direction of the electrolytic fluid flow 149, without departing from the scope of the disclosure.

[0073] The anode basket 165 can also include a ceiling or cover 169. The cover 169 can have a first upstream surface 169a facing the basket interior 167, and an opposing second downstream surface 169b facing the cathode 180. In non-limiting aspects, the second downstream surface 169b can have a surface geometry that matches or complements the cathode 180 or the metallic component 138 to be formed.

[0074] The cover 169 can define a set of second apertures 169c 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 169c 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 169c can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic including, for example, the velocity and the 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.

[0075] In operation, and with simultaneous reference to FIGS. 2A and 2B, the bath tank 145 can contain a suitable amount or level of the electrolytic solution 148, sufficient to cover or immerse the electrolytic solution 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 143. The electrolytic solution 148 flows into the electrolytic solution injection manifold 150 which injects the electrolytic solution 148 from the set of fluid injection nozzles 159, toward the anode 160 to define the electrolytic fluid flow 149. The electrolytic fluid flow 149, flows through the first apertures 166a, and flows in fluid communication with the anodic material 160a contained in the anode basket 165 and through gaps or spaces defined between and around the anodic material 160a. In non-limiting aspects, the electrolytic fluid flow 149 can then flow from the anode 160 toward the cathode shield 170.

[0076] The power supply 190 can operatively create the electric field 193 across the electrolytic solution 148 between the anode 160 and cathode 180 and can provide the electrical current 195 to the anode 160 and from the anode 160 through the electrolytic solution 148 to the cathode 180. The electrical current 195 causes metal ions from the anodic 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 (FIG. 1).

[0077] An electrodeposition rate of the anodic material 160a at any particular region of the cathode 180 will depend in part on a variety of factors, including characteristics of 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 anode 160 to modulate the electric field 193 or guide the electrolytic fluid flow 149, or both. By configuring the anode 160 as a conforming anode 160 aspects can arrange an even electric field strength across the surface of the cathode 180 and can reduce stagnation zones or uneven flow of the electrolytic fluid flow 149.

[0078] Such arrangements can provide a more uniform distribution of current density, and the anodic material 160a can be deposited onto the mandrel 182 more uniformly than in conventional techniques.

[0079] Additionally, or alternatively, in non-limiting aspects, the characteristics of the electrolytic fluid flow 149 can be further 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 through the bath tank 145. 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 fluid injection nozzles 159 as desired. In this way, the configuration of the anode 160, the electrolytic solution injection manifold 150 or the set of fluid injection nozzles 159, and combinations thereof, can cooperate to achieve a final thickness profile of the metallic component 138 as desired (e.g., flat), compensating for any non-uniform thickness profile that would otherwise be observed without the electrolytic solution injection manifold 150 in place.

[0080] FIG. 3 depicts a block diagram of another non-limiting aspect of a system 210 for carrying out an electroforming process for forming a metallic component 138 as disclosed herein. The system 210 of FIG. 3 is similar to the system 110 depicted in FIGS. 2A-2B so like parts are labelled with like reference numbers. One notable difference between the system 210 of FIG. 3 and the system 110 of FIGS. 2A-2B is that the system 210 further includes a gas inlet duct 142, and a gas injection manifold 130 defining a set of openings or gas injection nozzles 132. The gas injection manifold 130 can be submersed or disposed in the electrolytic solution 148 upstream of the cathode 180 (e.g., with respect to the electrolytic fluid flow 149). As illustrated, in non-limiting aspects, the anode 160 can be disposed between the gas injection manifold 130 and the cathode 180. In other non-limiting aspects, the gas injection manifold 130 can be disposed between the anode 160 and the cathode 180. Any number of the mechanical brackets or hangers 145a can be used to position the gas injection manifold 130. The system 210 can include a gas source 137 such as an air pump or pressurized gas tank fluidly coupled to the gas injection manifold 130 for providing a gas 135 (e.g., oxygen) thereto.

[0081] The gas source 137 can be coupled in fluid communication with the gas inlet duct 142 to arrange a gaseous flow (indicated by the series of dashed arrows “139”) of the gas 135 into the electrolytic solution 148 within the bath tank 145. The gas inlet duct 142 is coupled in fluid communication with the gas injection manifold 130 to provide the gaseous flow 139 thereto.

[0082] The gas injection manifold 130 can include at least one wall 130a arranged to define a manifold interior 136. The at least one wall 130a can further define the set of gas injection nozzles 132 therethrough. As such, the manifold interior 136 defines a passageway for the gaseous flow 139, in fluid communication with the set of gas injection nozzles 132. The gas injection manifold 130 is coupled in fluid communication to the gas inlet duct 142 to receive the gaseous flow 139 therefrom. In this way, the gaseous flow 139 can be arranged to flow from the gas injection manifold 130 toward the cathode 180. For example, the gaseous flow 139 can flow from upstream to downstream, from the gas inlet duct 142 to the gas injection manifold 130, then radially outward through the set of gas injection nozzles 132 into the bath tank 145 toward the cathode 180.

[0083] In operation, the system 210 of FIG. 3 operates similarly to the system 110 of FIGS. 2A-2B. However, the system 210 can additionally provide the gaseous flow 139 from the gas injection manifold 130 through the electrolytic solution 148 in the bath tank 145 during the electroforming operation. The gaseous flow 139 can flow toward and through the anode basket 165, or the anodic material 160a, or both. In such aspects, the gaseous flow 139 can operatively agitate the anodic material 160a. The agitation of the anodic material 160a by the gaseous flow 139 can reduce anode bridging without need of a mechanical agitator (e.g., to shake or agitate the anode basket 165). Additionally, the gaseous flow 139 can flow toward and impact the cathode 180 and can further agitate or dislodge gas bubbles that may have formed on the mandrel surface 185a. The agitation by the gaseous flow 139 of any gas bubbles formed on the mandrel surface 185a can reduce pitting on the metallic component 138 without need of a mechanical agitator (e.g., to shake or agitate the cathode 180).

[0084] While the exemplary gas injection manifold 130 is shown in FIG. 3 as being disposed upstream of the anodic material 160a, and supported by the hangers 145a, other aspects are not so limited, and the gas injection manifold 130 can be supported and arranged in any number of other ways without departing from the scope of the disclosure herein.

[0085] For example, FIG. 4 depicts a portion of another exemplary system 310 for carrying out an electroforming process for forming a metallic component 138, illustrating only the anode 160 and gas injection manifold 130, with other parts omitted for clarity.

[0086] The system 310 of FIG. 4 is similar to the system 110, 210 depicted in FIGS. 2A-2B and 3 so like parts are labelled with like reference numbers. One notable difference between the system 310 of FIG. 4 and the system 110, 210 of FIGS. 2A-2B and 3 is that the system 310 further depicts an exemplary aspect in which the gas injection manifold 130 is supported by the anode basket 165, and is between the anodic material 160a and the cathode 180. Another difference between the system 310 of FIG. 4 and the system 310 of FIG. 4 and the system 210 of FIG. 3 is that the system 310 of FIG. 4 does not include the electrolytic solution injection manifold 150.

[0087] In the exemplary instance depicted, the cover 169 can define a groove or slot 269 therein. The gas injection manifold 130 can be disposed within the slot 269 and can be supported by the anode basket 165. Brackets or straps (not shown) can be used to retain the gas injection manifold 130 within the slot 269. In other aspects, the gas injection manifold 130 can be supported by any other part of the anode basket 165 as desired without departing from the scope of the disclosure herein.

[0088] By disposing the gas injection manifold 130 proximal to the cathode 180, (e.g., between the anode 160 and the cathode 180), the gaseous flow 139 can more readily agitate or dislodge gas bubbles that may have formed on the cathode 180, or the metallic component 138, than when the gas injection manifold 130 is disposed between the anodic material 160a and the cathode 180.

[0089] FIG. 5 depicts a block diagram of another non-limiting aspect of a system 410 for carrying out an electroforming process for forming a metallic component 138 as disclosed herein. The system 410 of FIG. 5 is similar to the system 110, 210, 310 depicted in FIGS. 2A-2B and 3-4 so like parts are labelled with like reference numbers. One notable difference between the system 310 of FIG. 5 and the system 110, 210, 310 of FIGS. 2A-2B and 3-4 is that the system 410 further includes a cathode shield 170.

[0090] 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 electrolytic solution injection manifold 150 and the cathode shield 170. Any number of mechanical brackets, supports, or hangers 145a can be used to position the electrolytic solution injection manifold 150, the anode 160, the cathode shield 170, and the cathode 180 in the bath tank 145 as desired.

[0091] 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.

[0092] 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.

[0093] In non-limiting aspects, the electrolytic fluid flow 149 can 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.

[0094] An electrodeposition rate of the anodic material 160a at a particular region of the cathode 180 will depend in part on a variety of factors, including characteristics of 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.

[0095] 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.

[0096] 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 further controlled by 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.

[0097] Advantageously, the system for electroforming a metallic component described herein allows improved control of the thickness of the electroformed metallic component over conventional techniques. Furthermore, the method provides for generating a metallic component that has a decreased porosity over conventional methods. The decreased porosity afforded by the method can enhance aerodynamic performance of the metallic component when used as a fan blade shield. Additionally, the system and method 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, and reduced porosity, as compared with that of a similar metallic component formed by conventional systems.

[0098] FIG. 6 illustrates a method 300 for electroforming 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, 210, 310, 410 depicted in FIGS. 2A-5, 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.

[0099] The method 300 begins at 305 with disposing an electrolytic solution 148 into a bath tank 145. The bath tank can have a fluid inlet duct 141 and a fluid outlet duct 143, the fluid inlet duct 141 and the fluid outlet duct 143 fluidly coupled with the electrolytic solution 148.

[0100] 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).

[0101] The method 300 can include, at 315, immersing an electrolytic solution injection manifold 150 including the set of fluid injection nozzles 159 in the electrolytic solution 148 in the bath tank 145. In non-limiting aspects, the electrolytic solution 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 fluid injection nozzles 159 therethrough. In non-limiting aspects, the manifold interior 158 can define a passageway for the electrolytic fluid flow 149, in fluid communication with the set of fluid injection nozzles 159.

[0102] The method 300 can further include, at 340, injecting the electrolytic solution 148 from the electrolytic solution 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 electrolytic solution injection manifold 150 to the fluid outlet duct 143. 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 electrolytic solution injection manifold 150, then radially outward through the set of fluid injection nozzles 159 into the bath tank 145 toward the anode 160. For example, in non-limiting aspects, the fluid inlet duct 141 and the fluid outlet duct 143 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 electrolytic solution injection manifold 150, to the anode 160, to a cathode 180, and to the fluid outlet duct 143.

[0103] In non-limiting aspects the injecting the electrolytic solution 148 from the electrolytic solution injection manifold 150 into the bath tank 145 can include, fluidly coupling the electrolytic solution 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 143 to receive the electrolytic solution 148 therefrom. In non-limiting aspects, the injecting the electrolytic solution 148 from the electrolytic solution injection manifold 150 into the bath tank 145 can further include, 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 144 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 144 can include, by way of non-limiting example, a chemical filtering media. Optionally, a heater 146 can be provided to regulate a temperature of the electrolytic solution 148 in the bath tank 145. In non-limiting examples, the heater 146 can be disposed within the bath tank 145 or proximate the bath tank 145 exterior to the bath tank 145. Alternatively, the heater 146 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.

[0104] In non-limiting aspects, the injecting the electrolytic solution 148 from the electrolytic solution injection manifold 150 into the bath tank 145 can further include, fluidly pumping the electrolytic solution 148 from the fluid inlet duct 141 to the electrolytic solution injection manifold 150.

[0105] The method 300 can include, at 345, disposing the anode 160 in the bath tank 145 downstream of the electrolytic solution injection manifold 150. For example, the anode 160 can be a conforming anode 160 having a surface geometry that conforms to or complements a surface geometry of cathode 180 (e.g., the exterior mandrel surface 185a) or a surface geometry of the metallic component 138 to be formed.

[0106] 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.

[0107] 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 second 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.

[0108] 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 169c 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 169c 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.

[0109] The method 300 can include, at 347, immersing a gas injection manifold 130 including a set of gas injection nozzles 132 in the electrolytic solution 148 in the bath tank 145. The gas injection manifold 130 can be submersed or disposed in the electrolytic solution 148 upstream of a cathode 180 with respect to the electrolytic fluid flow 149. For example, in non-limiting aspects, the gas injection manifold 130 can be disposed between the anode 160 and the cathode 180. Any number of the mechanical brackets or hangers 145a can be used to position the gas injection manifold 130. In non-limiting aspects, a gas source 137 such as an air pump or pressurized gas tank can be fluidly coupled to the gas injection manifold 130 to provide a gas 135 (e.g., oxygen) thereto.

[0110] The gas source 137 can be coupled in fluid communication with the gas inlet duct 142 to arrange a gaseous flow 139 of the gas 135 into the electrolytic solution 148 within the bath tank 145. The gas inlet duct 142 can be coupled in fluid communication with the gas injection manifold 130 to provide the gaseous flow 139 thereto.

[0111] In non-limiting aspects, the method 300 can include, at 348, injecting the gas 135 from the gas injection manifold 130 into the bath tank 145 to define gaseous flow 139 within the bath tank 145. The gaseous flow 139 can extend from the gas injection manifold 130 to the cathode 180.

[0112] In non-limiting aspects the injecting the gas 135 from the gas injection manifold 130 into the bath tank 145 can include coupling the gas injection manifold 130 in fluid communication with a gas inlet duct 142, and coupling a gas source 137 in fluid communication with the gas inlet duct 142 to provide the gas 135 thereto. In non-limiting aspects, the injecting the gas 135 from the gas injection manifold 130 into the bath tank 145 can include pumping the gas from the gas inlet duct 142 to the gas injection manifold 130.

[0113] In non-limiting aspects, the gas injection manifold 130 can be supported by the anode basket 165, and can be disposed downstream, with respect to the electrolytic fluid flow 149, of the anodic material 160a.

[0114] In the exemplary instance depicted, the anode basket cover 169 can define a groove or slot 269 therein. The gas injection manifold 130 can be disposed within the slot 269 and can be supported by the anode basket 165. Brackets or straps (not shown) can be used to retain the gas injection manifold 130 within the slot 269. In other aspects, the gas injection manifold 130 can be supported by any other part of the anode basket 165 as desired without departing from the scope of the disclosure herein.

[0115] 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 a mandrel body 185. The mandrel body 185 can have an exterior mandrel surface 185a. The exterior mandrel surface 185a is shaped and arranged to conform to the desired shape of the metallic component 138 to be electroformed. The exterior mandrel surface 185a can be formed of an electrically conductive material (e.g., a coating). For example, in non-limiting aspects, the electrically conductive material can be formed of, without limitation, copper, silver, or nickel. In non-limiting aspects, the electrically conductive material can be applied to the mandrel 182 via a spray, painting, coating, or similar treatment to facilitate formation of the cathode 180.

[0116] 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.

[0117] The method 300 can include, at 355, electrically coupling the power supply 190 to the anode 160 and the cathode 180 to provide an electrical current 195 therebetween through the electrolytic solution 148. The 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 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.

[0118] 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.

[0119] In non-limiting aspects, the cathode shield 170 can include 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.

[0120] Advantageously, the method described herein allows improved control of the thickness of the electroformed metallic component over conventional techniques. Furthermore, the method provides for generating a metallic component that has a decreased porosity over conventional methods. The decreased porosity afforded by the method can enhance aerodynamic performance of the metallic component when used as a fan blade shield. Additionally, the system and method 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 thickness control, and combinations thereof, as compared with that of a similar metallic component formed by a different method.

[0121] 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.

[0122] 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.

[0123] Further aspects of the disclosure are provided by the subject matter of the following clauses:

[0124] A system for electroforming a metallic component, comprising: a bath tank configured to hold an electrolytic solution, the bath tank having a gas inlet duct fluidly coupled with the electrolytic solution; an anode disposed in the bath tank; a cathode disposed in the bath tank spaced from the anode; an electrical power supply electrically coupled to the anode and the cathode to provide an electrical current from the anode to the cathode through the electrolytic solution in the bath tank; gas source coupled in fluid communication with the gas inlet duct to provide a gas thereto; and a gas injection manifold disposed in the bath tank and coupled in fluid communication with the gas inlet duct to receive the gas therefrom, the gas injection manifold including a set of gas injection nozzles configured to inject the gas therefrom into the electrolytic solution within the bath tank to define a gaseous flow, the gaseous flow extending from the gas injection manifold to the cathode.

[0125] The system of any preceding clause, wherein the gas injection nozzles are axially spaced from each other along a length of the gas injection manifold.

[0126] The system of any preceding clause, wherein the anode includes an anode basket configured to support an anodic material.

[0127] The system of any preceding clause, wherein the anode basket is formed from an electrically conductive material.

[0128] The system of any preceding clause, wherein the gas injection manifold is coupled to the anode basket.

[0129] The system of any preceding clause, wherein the anode basket defines a slot, and wherein the gas injection manifold is disposed within the slot.

[0130] The system of any preceding clause, wherein the gas injection manifold is disposed between the anode and the cathode.

[0131] The system of any preceding clause, further including a cathode shield disposed between the anode and the cathode.

[0132] The system of any preceding clause, wherein the metallic component is a fan blade shield for a fan blade.

[0133] The system of any preceding clause, wherein the bath tank further includes a fluid inlet duct and a fluid outlet duct, both fluidly coupled with the electrolytic solution, the system further including: a fluid pump coupled in fluid communication with the fluid outlet duct to receive the electrolytic solution therefrom, and further coupled in fluid communication with the fluid inlet duct to provide the electrolytic solution thereto; and an electrolytic solution injection manifold fluidly coupled with the fluid inlet duct to receive the electrolytic solution therefrom, the electrolytic solution injection manifold including a set of fluid 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 flowing toward the anode and downstream toward the cathode.

[0134] The system of any preceding clause, wherein the anode includes an anode basket configured to support an anodic material, and wherein the anode basket defines a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

[0135] A method of electroforming a metallic component, the method comprising: disposing an electrolytic solution into a bath tank having a gas inlet duct; immersing a gas injection manifold including a set of gas injection nozzles in the electrolytic solution in the bath tank in fluid communication with the gas inlet duct to receive a gas therefrom; injecting the gas from the gas injection manifold into the bath tank to define a gaseous flow within the bath tank; disposing an anode in the bath tank; disposing a cathode in the bath tank spaced from the anode; and electrically coupling a power supply to the anode and the cathode to provide an electrical current therebetween through the electrolytic solution.

[0136] The method of any preceding clause, wherein the gas injection nozzles are axially spaced from each other along a length of the gas injection manifold.

[0137] The method of any preceding clause, wherein the gas injection manifold is disposed between the anode and the cathode.

[0138] The method of any preceding clause, wherein the anode includes an anode basket configured to support an anodic material.

[0139] The method of any preceding clause, wherein the anode basket is formed from an electrically conductive material.

[0140] The method of any preceding clause, wherein the gas injection manifold is coupled to the anode basket.

[0141] The method of any preceding clause, wherein the anode basket defines a slot, and wherein the gas injection manifold is disposed within the slot.

[0142] The method of any preceding clause, further comprising: immersing an electrolytic solution injection manifold including a set of fluid injection nozzles in the electrolytic solution in the bath tank; and injecting the electrolytic solution from the electrolytic solution injection manifold into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow flowing toward the anode and downstream toward the cathode.

[0143] The method of any preceding clause, wherein the anode basket defines a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

Examples

Embodiment Construction

[0012]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, and reduced cross anode and cathode interactions over conventional methods and systems.

[0013]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.

[0014]Reference will now be made in d...

TECHNICAL FIELD

[0001] The disclosure generally relates to metallic components and, more particularly, relates to a system 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 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 schematic illustration of a system for forming a metallic component according to another exemplary aspect of the present disclosure.

[0009] FIG. 4 is a schematic illustration of a portion of a system for forming a metallic component according to yet another exemplary aspect of the present disclosure.

[0010] FIG. 5 is a schematic illustration of a system for forming a metallic component according to still another exemplary aspect of the present disclosure.

[0011] FIG. 6 is a flow diagram illustrating a method of electroforming a metallic component according to an exemplary aspect of the present disclosure.DETAILED DESCRIPTION

[0012] 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, and reduced cross anode and cathode interactions over conventional methods and systems.

[0013] 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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, anodic material, cathode material, electrolytic solution properties such as an ion concentration, conductivity, resistivity, temperature, viscosity, pH level, chemical stability, additives, impurities, and the like.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] Additionally, strikes by relatively smaller foreign objects (e.g., sand) can progressively erode the blade material resulting in degraded performance of the fan and engine.

[0029] 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 the fan blade leading edge. The fan blade shields also allow the energy of the impact to be transmitted through the fan blade shield over a larger area than the impact position.

[0030] 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.

[0031] Titanium and alloys thereof provide high strength to weight ratios, good temperature and chemical resistance, and relatively 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.

[0032] 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.

[0033] 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 anodic material is dissolved by electrochemical action to continuously replenish the metallic content of the electrolyte which is consumed as a result of plating or forming on the article. The anodic 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.

[0034] 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 anodic material. The anodic material can be formed as relatively small pieces (sometimes referred to as fines, coins, pellets, 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 anodic material contained therein through openings provided in the anode basket. In operation, the anodic material can be gradually consumed and replaced as necessary at appropriate intervals.

[0035] 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, it is removed. The electro-deposited 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.

[0036] 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.

[0037] One problem with conventional techniques for electroforming metallic components is that, since the material deposition speed is directly proportional to current density, any non-uniformity of the distribution of the current density between the anode and the cathode can require more time to achieve a desired thickness of the deposited material, resulting in a time consuming and costly process. Portions of the cathode which are closer to the anode (e.g., protruding areas) are exposed to a higher current density so more metal is plated onto the protruding areas of the cathode than onto the portions of the cathode farther from the anode (e.g., recessed areas). A faster deposition in protruding areas consequently increases the current density and thus increases the deposition rate in the protruding areas, and likewise reduces the deposition rate in the recessed areas. Such uneven distribution of current density results in not only uneven distribution of the deposited material but can also lead to dendrite or like crystalline formations forming on the cathode. Typically, to reduce the formation of crystalline formations, a conventional electroforming process is often conducted at a minimum current density thus requiring extensive time for an electroformed metal layer to reach a desired thickness. However, even at a low current density uneven material deposition can still occur. In some cases, the electroforming process can be interrupted, and the object removed from the electrolytic solution, to perform an additional step of cutting or removing dendrite and part of the metal deposited at the protruding areas to reduce the increasing current density at these areas. Electroforming at a higher current density accelerates the deposition rate, but worsens the non-uniformity and increases the rate of dendrite buildup.

[0038] Another problem in conventional electroforming operations, is that as the individual pieces of anodic material gradually decrease in size over time, voids are created in the anodic material due to bridging of individual anode pieces. Such bridging prevents the anodic material from settling to the bottom of the anode basket as it is consumed, and thus prevents the formation of sufficient room for the addition of new anodic material to the anode basket. The bridging also results in a variable quantity of anodic material in contact with the electrolyte over time resulting in poor uniformity of the deposited material and increased porosity on the electro-formed surface.

[0039] 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 anodic 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 anodic material. Such techniques and / or mechanisms can add additional costs, and in some cases can result in damage the basket.

[0040] Yet another problem associated with conventional electroforming techniques is an inherent formation of gas bubbles (e.g., hydrogen) on a surface of the cathode during electroforming. Such bubbles can result in undesired pitting or porosity on a surface of the electroformed component.

[0041] 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 of electroforming fan blade shields, with improved operational efficiency and reasonable cost.

[0042] For example, aspects as disclosed herein can provide a gas injection manifold to operatively inject a gaseous flow into the electrolytic solution during electroforming operations, which can agitate, dislodge, or otherwise remove the gas bubbles formed on the cathode surface. Furthermore, when arranged upstream of the anode, the gas injection manifold can additionally inject the gaseous flow into the electrolytic solution during electroforming operations, to agitate the anode basket to settle the anodic material to thereby reduce bridging of the anodic material without need of a mechanical agitator.

[0043] Aspects as disclosed herein can additionally 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. The electrolytic fluid flow can enable a controlled flow of ions through the electrolytic solution, to 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.

[0044] Systems and methods disclosed herein provide for generating a metallic component that has a decreased porosity and pitting of the metallic component over conventional methods. The decreased porosity and pitting afforded by the aspects disclosed herein can enhance aerodynamic performance of the metallic component when used as a fan blade shield.

[0045] Non-limiting aspects as disclosed herein can also provide a conforming anode, having a shape that conforms to a shape of the cathode to provide an even distribution of current density and a consequent even distribution of the deposited material Additionally, aspects disclosed herein can include a cathode shield placed between the anode and cathode to influence or direct the electrical current through the electrolytic solution from the anode and the cathode, to further arrange an even flow of ions through the electrolytic solution, resulting in an even deposition of anodic material onto the cathode.

[0046] 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 a LP turbine 36, and an exhaust section 38.

[0047] 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.

[0048] 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 the 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] FIG. 2A depicts a schematic illustration of non-limiting aspect of a system 110 for electroforming 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 143. The system 110 can further include an electrolytic solution injection manifold 150 defining a set of openings or fluid injection nozzles 159. An anode 160, a cathode 180, and the electrolytic solution injection manifold 150 can be submerged or disposed in the electrolytic solution 148. The anode 160 is spaced from the cathode 180. The anode 160 is disposed between the electrolytic solution injection manifold 150 and the cathode 180. Any number of mechanical brackets or hangers 145a can be used to position the electrolytic solution injection manifold 150, the anode 160, and the cathode 180 in the bath tank 145 as desired. The system 110 can further include a fluid pump 147. A power supply 190 (e.g., a DC electrical power supply) can be disposed outside of the bath tank 145 and electrically coupled to the anode 160 and the cathode 180.

[0061] 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)).

[0062] The fluid pump 147 is coupled in fluid communication with the fluid inlet duct 141 and the fluid outlet duct 143 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 electrolytic solution injection manifold 150 to provide the electrolytic solution 148 thereto. The fluid outlet duct 143 is arranged in fluid communication with the electrolytic solution 148 disposed in the bath tank 145 to receive the electrolytic fluid flow 149 therefrom.

[0063] 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 143 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 143 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 143 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 electrolytic solution injection manifold 150, to the anode 160, to the cathode 180, and to the fluid outlet duct 143.

[0064] 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 143. In some non-limiting aspects, a filter 144 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 144 can include, by way of non-limiting example, a chemical filtering media. Optionally, a heater 146 can be provided to regulate the temperature of the electrolytic solution 148 in the bath tank 145. In non-limiting examples, the heater 146 can be disposed within the bath tank 145 or proximate the bath tank 145 exterior to the bath tank 145. Alternatively, the heater 146 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.

[0065] The 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 power supply 190 can operatively creates 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 power supply 190 and the anode 160 and cathode 180. The 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 (not shown) to move from the anode 160 to the cathode 180 and deposit thereon.

[0066] A surface geometry of the cathode 180 can be based on or conform to a desired geometry of the metallic component 138 to be electroformed. In non-limiting aspects, the cathode 180 can include a mandrel 182 having a mandrel body 185. The mandrel body 185 can have an exterior mandrel surface 185a. The mandrel surface 185a is shaped and arranged to conform to the desired shape of the metallic component 138 to be electroformed. The exterior mandrel surface 185a can be formed of an electrically conductive material (e.g., a coating). For example, in non-limiting aspects, the electrically conductive material can be, without limitation, copper, silver, or nickel. It is contemplated that the electrically conductive material can be applied to the mandrel body 185 via a spray, painting, coating, or similar treatment to facilitate formation of the cathode 180.

[0067] The mandrel body 185 can be 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.

[0068] In non-limiting aspects, the anode 160 can be a conforming anode. For example, the anode 160 can have a surface geometry that conforms to or complements a surface geometry of cathode 180 (e.g., the exterior mandrel surface 185a) or a surface geometry of the metallic component 138 to be formed. In other aspects, the anode 160 can be a non-conforming anode

[0069] 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. As illustrated, the electrolytic solution injection manifold 150 can include at least one wall 150a arranged to define a manifold interior 158. The at least one wall 150a can further define the set of fluid 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 fluid injection nozzles 159. The electrolytic solution injection manifold 150 is coupled in fluid communication to the first 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 electrolytic solution injection manifold 150, then radially outward through the set of fluid injection nozzles 159 into the bath tank toward the anode 160.

[0070] 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. 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. In non-limiting aspects, the anode 160 can include a container or anode basket 165 arranged to hold or support the anodic material 160a. The anodic material 160a can be disposed in, or on, the anode basket 165. In such aspects, the anode basket 165 can have a surface geometry that matches or complements the cathode 180 or the metallic component 138 to be formed.

[0071] 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 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 second outward-facing surface 164b facing an exterior of the anode basket 165.

[0072] The anode basket 165 also includes 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 166b for the anodic material 160a. In non-limiting aspects, support surface 166b can have a surface geometry that matches or conforms to a surface geometry of the cathode 180 or the metallic component 138 to be formed. 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, a velocity and a direction of the electrolytic fluid flow 149, without departing from the scope of the disclosure.

[0073] The anode basket 165 can also include a ceiling or cover 169. The cover 169 can have a first upstream surface 169a facing the basket interior 167, and an opposing second downstream surface 169b facing the cathode 180. In non-limiting aspects, the second downstream surface 169b can have a surface geometry that matches or complements the cathode 180 or the metallic component 138 to be formed.

[0074] The cover 169 can define a set of second apertures 169c 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 169c 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 169c can be selectively configured to affect any desired electrolytic fluid flow 149 property or characteristic including, for example, the velocity and the 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.

[0075] In operation, and with simultaneous reference to FIGS. 2A and 2B, the bath tank 145 can contain a suitable amount or level of the electrolytic solution 148, sufficient to cover or immerse the electrolytic solution 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 143. The electrolytic solution 148 flows into the electrolytic solution injection manifold 150 which injects the electrolytic solution 148 from the set of fluid injection nozzles 159, toward the anode 160 to define the electrolytic fluid flow 149. The electrolytic fluid flow 149, flows through the first apertures 166a, and flows in fluid communication with the anodic material 160a contained in the anode basket 165 and through gaps or spaces defined between and around the anodic material 160a. In non-limiting aspects, the electrolytic fluid flow 149 can then flow from the anode 160 toward the cathode shield 170.

[0076] The power supply 190 can operatively create the electric field 193 across the electrolytic solution 148 between the anode 160 and cathode 180 and can provide the electrical current 195 to the anode 160 and from the anode 160 through the electrolytic solution 148 to the cathode 180. The electrical current 195 causes metal ions from the anodic 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 (FIG. 1).

[0077] An electrodeposition rate of the anodic material 160a at any particular region of the cathode 180 will depend in part on a variety of factors, including characteristics of 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 anode 160 to modulate the electric field 193 or guide the electrolytic fluid flow 149, or both. By configuring the anode 160 as a conforming anode 160 aspects can arrange an even electric field strength across the surface of the cathode 180 and can reduce stagnation zones or uneven flow of the electrolytic fluid flow 149.

[0078] Such arrangements can provide a more uniform distribution of current density, and the anodic material 160a can be deposited onto the mandrel 182 more uniformly than in conventional techniques.

[0079] Additionally, or alternatively, in non-limiting aspects, the characteristics of the electrolytic fluid flow 149 can be further 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 through the bath tank 145. 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 fluid injection nozzles 159 as desired. In this way, the configuration of the anode 160, the electrolytic solution injection manifold 150 or the set of fluid injection nozzles 159, and combinations thereof, can cooperate to achieve a final thickness profile of the metallic component 138 as desired (e.g., flat), compensating for any non-uniform thickness profile that would otherwise be observed without the electrolytic solution injection manifold 150 in place.

[0080] FIG. 3 depicts a block diagram of another non-limiting aspect of a system 210 for carrying out an electroforming process for forming a metallic component 138 as disclosed herein. The system 210 of FIG. 3 is similar to the system 110 depicted in FIGS. 2A-2B so like parts are labelled with like reference numbers. One notable difference between the system 210 of FIG. 3 and the system 110 of FIGS. 2A-2B is that the system 210 further includes a gas inlet duct 142, and a gas injection manifold 130 defining a set of openings or gas injection nozzles 132. The gas injection manifold 130 can be submersed or disposed in the electrolytic solution 148 upstream of the cathode 180 (e.g., with respect to the electrolytic fluid flow 149). As illustrated, in non-limiting aspects, the anode 160 can be disposed between the gas injection manifold 130 and the cathode 180. In other non-limiting aspects, the gas injection manifold 130 can be disposed between the anode 160 and the cathode 180. Any number of the mechanical brackets or hangers 145a can be used to position the gas injection manifold 130. The system 210 can include a gas source 137 such as an air pump or pressurized gas tank fluidly coupled to the gas injection manifold 130 for providing a gas 135 (e.g., oxygen) thereto.

[0081] The gas source 137 can be coupled in fluid communication with the gas inlet duct 142 to arrange a gaseous flow (indicated by the series of dashed arrows “139”) of the gas 135 into the electrolytic solution 148 within the bath tank 145. The gas inlet duct 142 is coupled in fluid communication with the gas injection manifold 130 to provide the gaseous flow 139 thereto.

[0082] The gas injection manifold 130 can include at least one wall 130a arranged to define a manifold interior 136. The at least one wall 130a can further define the set of gas injection nozzles 132 therethrough. As such, the manifold interior 136 defines a passageway for the gaseous flow 139, in fluid communication with the set of gas injection nozzles 132. The gas injection manifold 130 is coupled in fluid communication to the gas inlet duct 142 to receive the gaseous flow 139 therefrom. In this way, the gaseous flow 139 can be arranged to flow from the gas injection manifold 130 toward the cathode 180. For example, the gaseous flow 139 can flow from upstream to downstream, from the gas inlet duct 142 to the gas injection manifold 130, then radially outward through the set of gas injection nozzles 132 into the bath tank 145 toward the cathode 180.

[0083] In operation, the system 210 of FIG. 3 operates similarly to the system 110 of FIGS. 2A-2B. However, the system 210 can additionally provide the gaseous flow 139 from the gas injection manifold 130 through the electrolytic solution 148 in the bath tank 145 during the electroforming operation. The gaseous flow 139 can flow toward and through the anode basket 165, or the anodic material 160a, or both. In such aspects, the gaseous flow 139 can operatively agitate the anodic material 160a. The agitation of the anodic material 160a by the gaseous flow 139 can reduce anode bridging without need of a mechanical agitator (e.g., to shake or agitate the anode basket 165). Additionally, the gaseous flow 139 can flow toward and impact the cathode 180 and can further agitate or dislodge gas bubbles that may have formed on the mandrel surface 185a. The agitation by the gaseous flow 139 of any gas bubbles formed on the mandrel surface 185a can reduce pitting on the metallic component 138 without need of a mechanical agitator (e.g., to shake or agitate the cathode 180).

[0084] While the exemplary gas injection manifold 130 is shown in FIG. 3 as being disposed upstream of the anodic material 160a, and supported by the hangers 145a, other aspects are not so limited, and the gas injection manifold 130 can be supported and arranged in any number of other ways without departing from the scope of the disclosure herein.

[0085] For example, FIG. 4 depicts a portion of another exemplary system 310 for carrying out an electroforming process for forming a metallic component 138, illustrating only the anode 160 and gas injection manifold 130, with other parts omitted for clarity.

[0086] The system 310 of FIG. 4 is similar to the system 110, 210 depicted in FIGS. 2A-2B and 3 so like parts are labelled with like reference numbers. One notable difference between the system 310 of FIG. 4 and the system 110, 210 of FIGS. 2A-2B and 3 is that the system 310 further depicts an exemplary aspect in which the gas injection manifold 130 is supported by the anode basket 165, and is between the anodic material 160a and the cathode 180. Another difference between the system 310 of FIG. 4 and the system 310 of FIG. 4 and the system 210 of FIG. 3 is that the system 310 of FIG. 4 does not include the electrolytic solution injection manifold 150.

[0087] In the exemplary instance depicted, the cover 169 can define a groove or slot 269 therein. The gas injection manifold 130 can be disposed within the slot 269 and can be supported by the anode basket 165. Brackets or straps (not shown) can be used to retain the gas injection manifold 130 within the slot 269. In other aspects, the gas injection manifold 130 can be supported by any other part of the anode basket 165 as desired without departing from the scope of the disclosure herein.

[0088] By disposing the gas injection manifold 130 proximal to the cathode 180, (e.g., between the anode 160 and the cathode 180), the gaseous flow 139 can more readily agitate or dislodge gas bubbles that may have formed on the cathode 180, or the metallic component 138, than when the gas injection manifold 130 is disposed between the anodic material 160a and the cathode 180.

[0089] FIG. 5 depicts a block diagram of another non-limiting aspect of a system 410 for carrying out an electroforming process for forming a metallic component 138 as disclosed herein. The system 410 of FIG. 5 is similar to the system 110, 210, 310 depicted in FIGS. 2A-2B and 3-4 so like parts are labelled with like reference numbers. One notable difference between the system 310 of FIG. 5 and the system 110, 210, 310 of FIGS. 2A-2B and 3-4 is that the system 410 further includes a cathode shield 170.

[0090] 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 electrolytic solution injection manifold 150 and the cathode shield 170. Any number of mechanical brackets, supports, or hangers 145a can be used to position the electrolytic solution injection manifold 150, the anode 160, the cathode shield 170, and the cathode 180 in the bath tank 145 as desired.

[0091] 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.

[0092] 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.

[0093] In non-limiting aspects, the electrolytic fluid flow 149 can 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.

[0094] An electrodeposition rate of the anodic material 160a at a particular region of the cathode 180 will depend in part on a variety of factors, including characteristics of 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.

[0095] 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.

[0096] 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 further controlled by 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.

[0097] Advantageously, the system for electroforming a metallic component described herein allows improved control of the thickness of the electroformed metallic component over conventional techniques. Furthermore, the method provides for generating a metallic component that has a decreased porosity over conventional methods. The decreased porosity afforded by the method can enhance aerodynamic performance of the metallic component when used as a fan blade shield. Additionally, the system and method 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, and reduced porosity, as compared with that of a similar metallic component formed by conventional systems.

[0098] FIG. 6 illustrates a method 300 for electroforming 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, 210, 310, 410 depicted in FIGS. 2A-5, 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.

[0099] The method 300 begins at 305 with disposing an electrolytic solution 148 into a bath tank 145. The bath tank can have a fluid inlet duct 141 and a fluid outlet duct 143, the fluid inlet duct 141 and the fluid outlet duct 143 fluidly coupled with the electrolytic solution 148.

[0100] 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).

[0101] The method 300 can include, at 315, immersing an electrolytic solution injection manifold 150 including the set of fluid injection nozzles 159 in the electrolytic solution 148 in the bath tank 145. In non-limiting aspects, the electrolytic solution 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 fluid injection nozzles 159 therethrough. In non-limiting aspects, the manifold interior 158 can define a passageway for the electrolytic fluid flow 149, in fluid communication with the set of fluid injection nozzles 159.

[0102] The method 300 can further include, at 340, injecting the electrolytic solution 148 from the electrolytic solution 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 electrolytic solution injection manifold 150 to the fluid outlet duct 143. 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 electrolytic solution injection manifold 150, then radially outward through the set of fluid injection nozzles 159 into the bath tank 145 toward the anode 160. For example, in non-limiting aspects, the fluid inlet duct 141 and the fluid outlet duct 143 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 electrolytic solution injection manifold 150, to the anode 160, to a cathode 180, and to the fluid outlet duct 143.

[0103] In non-limiting aspects the injecting the electrolytic solution 148 from the electrolytic solution injection manifold 150 into the bath tank 145 can include, fluidly coupling the electrolytic solution 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 143 to receive the electrolytic solution 148 therefrom. In non-limiting aspects, the injecting the electrolytic solution 148 from the electrolytic solution injection manifold 150 into the bath tank 145 can further include, 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 144 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 144 can include, by way of non-limiting example, a chemical filtering media. Optionally, a heater 146 can be provided to regulate a temperature of the electrolytic solution 148 in the bath tank 145. In non-limiting examples, the heater 146 can be disposed within the bath tank 145 or proximate the bath tank 145 exterior to the bath tank 145. Alternatively, the heater 146 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.

[0104] In non-limiting aspects, the injecting the electrolytic solution 148 from the electrolytic solution injection manifold 150 into the bath tank 145 can further include, fluidly pumping the electrolytic solution 148 from the fluid inlet duct 141 to the electrolytic solution injection manifold 150.

[0105] The method 300 can include, at 345, disposing the anode 160 in the bath tank 145 downstream of the electrolytic solution injection manifold 150. For example, the anode 160 can be a conforming anode 160 having a surface geometry that conforms to or complements a surface geometry of cathode 180 (e.g., the exterior mandrel surface 185a) or a surface geometry of the metallic component 138 to be formed.

[0106] 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.

[0107] 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 second 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.

[0108] 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 169c 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 169c 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.

[0109] The method 300 can include, at 347, immersing a gas injection manifold 130 including a set of gas injection nozzles 132 in the electrolytic solution 148 in the bath tank 145. The gas injection manifold 130 can be submersed or disposed in the electrolytic solution 148 upstream of a cathode 180 with respect to the electrolytic fluid flow 149. For example, in non-limiting aspects, the gas injection manifold 130 can be disposed between the anode 160 and the cathode 180. Any number of the mechanical brackets or hangers 145a can be used to position the gas injection manifold 130. In non-limiting aspects, a gas source 137 such as an air pump or pressurized gas tank can be fluidly coupled to the gas injection manifold 130 to provide a gas 135 (e.g., oxygen) thereto.

[0110] The gas source 137 can be coupled in fluid communication with the gas inlet duct 142 to arrange a gaseous flow 139 of the gas 135 into the electrolytic solution 148 within the bath tank 145. The gas inlet duct 142 can be coupled in fluid communication with the gas injection manifold 130 to provide the gaseous flow 139 thereto.

[0111] In non-limiting aspects, the method 300 can include, at 348, injecting the gas 135 from the gas injection manifold 130 into the bath tank 145 to define gaseous flow 139 within the bath tank 145. The gaseous flow 139 can extend from the gas injection manifold 130 to the cathode 180.

[0112] In non-limiting aspects the injecting the gas 135 from the gas injection manifold 130 into the bath tank 145 can include coupling the gas injection manifold 130 in fluid communication with a gas inlet duct 142, and coupling a gas source 137 in fluid communication with the gas inlet duct 142 to provide the gas 135 thereto. In non-limiting aspects, the injecting the gas 135 from the gas injection manifold 130 into the bath tank 145 can include pumping the gas from the gas inlet duct 142 to the gas injection manifold 130.

[0113] In non-limiting aspects, the gas injection manifold 130 can be supported by the anode basket 165, and can be disposed downstream, with respect to the electrolytic fluid flow 149, of the anodic material 160a.

[0114] In the exemplary instance depicted, the anode basket cover 169 can define a groove or slot 269 therein. The gas injection manifold 130 can be disposed within the slot 269 and can be supported by the anode basket 165. Brackets or straps (not shown) can be used to retain the gas injection manifold 130 within the slot 269. In other aspects, the gas injection manifold 130 can be supported by any other part of the anode basket 165 as desired without departing from the scope of the disclosure herein.

[0115] 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 a mandrel body 185. The mandrel body 185 can have an exterior mandrel surface 185a. The exterior mandrel surface 185a is shaped and arranged to conform to the desired shape of the metallic component 138 to be electroformed. The exterior mandrel surface 185a can be formed of an electrically conductive material (e.g., a coating). For example, in non-limiting aspects, the electrically conductive material can be formed of, without limitation, copper, silver, or nickel. In non-limiting aspects, the electrically conductive material can be applied to the mandrel 182 via a spray, painting, coating, or similar treatment to facilitate formation of the cathode 180.

[0116] 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.

[0117] The method 300 can include, at 355, electrically coupling the power supply 190 to the anode 160 and the cathode 180 to provide an electrical current 195 therebetween through the electrolytic solution 148. The 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 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.

[0118] 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.

[0119] In non-limiting aspects, the cathode shield 170 can include 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.

[0120] Advantageously, the method described herein allows improved control of the thickness of the electroformed metallic component over conventional techniques. Furthermore, the method provides for generating a metallic component that has a decreased porosity over conventional methods. The decreased porosity afforded by the method can enhance aerodynamic performance of the metallic component when used as a fan blade shield. Additionally, the system and method 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 thickness control, and combinations thereof, as compared with that of a similar metallic component formed by a different method.

[0121] 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.

[0122] 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.

[0123] Further aspects of the disclosure are provided by the subject matter of the following clauses:

[0124] A system for electroforming a metallic component, comprising: a bath tank configured to hold an electrolytic solution, the bath tank having a gas inlet duct fluidly coupled with the electrolytic solution; an anode disposed in the bath tank; a cathode disposed in the bath tank spaced from the anode; an electrical power supply electrically coupled to the anode and the cathode to provide an electrical current from the anode to the cathode through the electrolytic solution in the bath tank; gas source coupled in fluid communication with the gas inlet duct to provide a gas thereto; and a gas injection manifold disposed in the bath tank and coupled in fluid communication with the gas inlet duct to receive the gas therefrom, the gas injection manifold including a set of gas injection nozzles configured to inject the gas therefrom into the electrolytic solution within the bath tank to define a gaseous flow, the gaseous flow extending from the gas injection manifold to the cathode.

[0125] The system of any preceding clause, wherein the gas injection nozzles are axially spaced from each other along a length of the gas injection manifold.

[0126] The system of any preceding clause, wherein the anode includes an anode basket configured to support an anodic material.

[0127] The system of any preceding clause, wherein the anode basket is formed from an electrically conductive material.

[0128] The system of any preceding clause, wherein the gas injection manifold is coupled to the anode basket.

[0129] The system of any preceding clause, wherein the anode basket defines a slot, and wherein the gas injection manifold is disposed within the slot.

[0130] The system of any preceding clause, wherein the gas injection manifold is disposed between the anode and the cathode.

[0131] The system of any preceding clause, further including a cathode shield disposed between the anode and the cathode.

[0132] The system of any preceding clause, wherein the metallic component is a fan blade shield for a fan blade.

[0133] The system of any preceding clause, wherein the bath tank further includes a fluid inlet duct and a fluid outlet duct, both fluidly coupled with the electrolytic solution, the system further including: a fluid pump coupled in fluid communication with the fluid outlet duct to receive the electrolytic solution therefrom, and further coupled in fluid communication with the fluid inlet duct to provide the electrolytic solution thereto; and an electrolytic solution injection manifold fluidly coupled with the fluid inlet duct to receive the electrolytic solution therefrom, the electrolytic solution injection manifold including a set of fluid 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 flowing toward the anode and downstream toward the cathode.

[0134] The system of any preceding clause, wherein the anode includes an anode basket configured to support an anodic material, and wherein the anode basket defines a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

[0135] A method of electroforming a metallic component, the method comprising: disposing an electrolytic solution into a bath tank having a gas inlet duct; immersing a gas injection manifold including a set of gas injection nozzles in the electrolytic solution in the bath tank in fluid communication with the gas inlet duct to receive a gas therefrom; injecting the gas from the gas injection manifold into the bath tank to define a gaseous flow within the bath tank; disposing an anode in the bath tank; disposing a cathode in the bath tank spaced from the anode; and electrically coupling a power supply to the anode and the cathode to provide an electrical current therebetween through the electrolytic solution.

[0136] The method of any preceding clause, wherein the gas injection nozzles are axially spaced from each other along a length of the gas injection manifold.

[0137] The method of any preceding clause, wherein the gas injection manifold is disposed between the anode and the cathode.

[0138] The method of any preceding clause, wherein the anode includes an anode basket configured to support an anodic material.

[0139] The method of any preceding clause, wherein the anode basket is formed from an electrically conductive material.

[0140] The method of any preceding clause, wherein the gas injection manifold is coupled to the anode basket.

[0141] The method of any preceding clause, wherein the anode basket defines a slot, and wherein the gas injection manifold is disposed within the slot.

[0142] The method of any preceding clause, further comprising: immersing an electrolytic solution injection manifold including a set of fluid injection nozzles in the electrolytic solution in the bath tank; and injecting the electrolytic solution from the electrolytic solution injection manifold into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow flowing toward the anode and downstream toward the cathode.

[0143] The method of any preceding clause, wherein the anode basket defines a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

Examples

Embodiment Construction

[0012]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, and reduced cross anode and cathode interactions over conventional methods and systems.

[0013]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.

[0014]Reference will now be made in d...

Claims

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

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

3. The system of claim 1, wherein the anode includes an anode basket configured to support an anodic material.

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

5. The system of claim 3, wherein the gas injection manifold is coupled to the anode basket.

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

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

8. The system of claim 1, further including a cathode shield disposed between the anode and the cathode.

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

10. The system of claim 1, wherein the bath tank further includes a fluid inlet duct and a fluid outlet duct, both fluidly coupled with the electrolytic solution, the system further including:a fluid pump coupled in fluid communication with the fluid outlet duct to receive the electrolytic solution therefrom, and further coupled in fluid communication with the fluid inlet duct to provide the electrolytic solution thereto; andan electrolytic solution injection manifold fluidly coupled with the fluid inlet duct to receive the electrolytic solution therefrom, the electrolytic solution injection manifold including a set of fluid 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 flowing toward the anode and downstream toward the cathode.

11. The system of claim 10, wherein the anode includes an anode basket configured to support an anodic material, andwherein the anode basket defines a set of first apertures therethrough, arranged to receive the electrolytic solution fluid flow therethrough in fluid communication with the anodic material.

12. A method of electroforming a metallic component, the method comprising:disposing an electrolytic solution into a bath tank having a gas inlet duct;immersing a gas injection manifold including a set of gas injection nozzles in the electrolytic solution in the bath tank in fluid communication with the gas inlet duct to receive a gas therefrom;injecting the gas from the gas injection manifold into the bath tank to define a gaseous flow within the bath tank;disposing an anode in the bath tank;disposing a cathode in the bath tank spaced from the anode; 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 gas injection nozzles are axially spaced from each other along a length of the gas injection manifold.

14. The method of claim 12, wherein the gas injection manifold is disposed between the anode and the cathode.

15. The method of claim 12, wherein the anode includes an anode basket configured to support an anodic material.

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

17. The method of claim 15, wherein the gas injection manifold is coupled to the anode basket.

18. The method of claim 17, wherein the anode basket defines a slot, and wherein the gas injection manifold is disposed within the slot.

19. The method of claim 14, further comprising:immersing an electrolytic solution injection manifold including a set of fluid injection nozzles in the electrolytic solution in the bath tank; andinjecting the electrolytic solution from the electrolytic solution injection manifold into the bath tank to define an electrolytic solution fluid flow within the bath tank, the electrolytic solution fluid flow flowing toward the anode and downstream toward the cathode.

20. The method of claim 19, 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.

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