Cold Spray Metallic Structure with Integrated Component

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Solution Overview

Problem

Conventional methods for forming sheet structures in gas turbine engines are expensive and time-consuming, especially as the complexity and size of the parts increase, due to the need for durable and costly dies that require extensive formation processes.

Innovation Solution

A method and system utilizing cold spraying to deposit a layer of material onto a secondary component and a main formation surface, with the secondary component having a textured bonding surface to enhance bonding, allowing for the formation of metallic structures with integrated components in a less expensive and time-efficient manner, including the use of a secondary tool that can be removed through etching or melting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional hot or cold forming using dies is used to form sheet structures, then the structural integrity and shape accuracy are improved, but the manufacturing cost and time consumption increase significantly

Engineering Contradiction:

Improveshape accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The forming process is segmented into two distinct stages: (1) forming the base structure using conventional dies, and (2) adding secondary components through cold spray deposition. This segmentation allows each stage to be optimized independently, reducing overall manufacturing complexity and cost while maintaining precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Secondary components are prepared in advance as separate entities with pre-formed geometries and bonding surfaces. These pre-prepared components are then integrated onto the main structure through cold spray deposition, eliminating the need for complex integrated tooling and reducing die formation time and cost.

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If conventional forming using dies is used for complex parts, then the structural integrity is maintained, but the die formation time and expense increase

Engineering Contradiction:

Improvestructural integrityVSAvoiddie formation time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The component is divided into a main structure formed by conventional dies and secondary components added later. This segmentation allows the main structure to be formed using proven, efficient die processes while secondary features are added separately, avoiding the need to create complex integrated dies for the entire assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Secondary components are manufactured separately in advance using appropriate processes, then integrated onto the main structure. This preliminary preparation eliminates the time-consuming task of forming complex integrated tooling and allows parallel processing of different component elements.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If cold spray deposition is used to form metallic structures with integrated components, then the manufacturing cost and time are reduced, but the bonding strength must be ensured

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidbonding strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The secondary components are designed with specific local properties: bonding surfaces with appropriate roughness (Ra 0.4-3.2 µm) to enhance mechanical interlocking, and material compositions matched to the substrate. This local optimization ensures strong bonding at the interface while maintaining overall manufacturing efficiency through the cold spray process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cold spray process parameters are optimized to achieve strong bonding: particle velocity, gas temperature, and deposition rate are controlled to ensure proper metallurgical bonding between the secondary component and substrate. The bonding surface parameters (roughness, composition, temperature) are also controlled to maximize adhesion strength.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces the cost and time required for forming complex sheet structures by using cold spraying to bond materials directly to the secondary component, enabling the creation of metallic structures with integrated components more efficiently and cost-effectively.

Implementation Method 1

depositing a layer of material on the secondary component and the main formation surface by cold spraying the layer of material such that the layer of material bonds to the secondary component

Methodology Applied

Scientific EffectCold spray deposition: Deposition (physical)

Implementation Method 2

cold spraying the layer of material at a velocity sufficiently great to cause the particles of the material to bond together and to the secondary component

Methodology Applied

Scientific EffectKinetic energy bonding: Impact Force

Implementation Method 3

the secondary component has a bonding surface configured to receive the layer of material, the bonding surface being textured to enhance bonding with the layer of material

Methodology Applied

Scientific EffectMechanical interlocking: Friction

Implementation Method 4

removing the secondary tool includes forming a hole in the layer of material and leaching the secondary tool from the layer of material through the hole via at least one of etching the secondary tool or melting the secondary tool

Methodology Applied

Scientific EffectEtching:

Implementation Method 5

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11479861B2Deposited material structure with integrated component

Publication Date: 2022.10.25 RTX CORP

AI summary

A method for forming a metallic structure having a secondary component includes positioning the secondary component on a main formation surface of a main tool, the main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing a layer of material on the secondary component and the main formation surface using a cold-spray technique such that the layer of material bonds to the secondary component. The method also includes removing the layer of material and the secondary component to form the metallic structure.