Cold-Spray Sheet Structure Formation
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Solution Overview
Problem
Conventional methods for forming sheet structures in gas turbine engines are expensive and time-consuming, particularly due to the complexity and cost of die materials and the formation process, which increases with the complexity of the part design.
Innovation Solution
A method using a cold-spray deposition technique where a tool with a formation surface corresponding to the desired shape is created, either through additive manufacturing or electroplating, and material is deposited and removed using physical force, releasing agents, or chemical etching to form sheet structures with varying thicknesses and features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hot or cold forming using dies is used to form sheet structures, then the sheet structures can be produced with consistent quality, but the cost and time required increase significantly, especially for complex parts
Solution Approach 1:
The sheet structure is formed by depositing material in multiple sequential layers on the die surface, with each layer contributing to the final complex geometry. This layer-by-layer deposition allows complex shapes to be built incrementally without requiring complex integrated dies
Solution Approach 2:
The die surface is prepared in advance with a release coating applied before material deposition. This preliminary action facilitates easy removal of the formed sheet structure after deposition, reducing cycle time and complexity of the overall forming process
2Reliability
If die materials capable of withstanding temperature and pressure loads are used, then the dies can endure the forming conditions, but the material cost and lead time increase
Solution Approach 1:
Instead of using static, pre-formed dies requiring lengthy manufacturing lead times, the system uses a depositable material that can be applied directly to a die surface. This dynamic approach allows the forming tool to be created quickly by deposition rather than through time-consuming die fabrication processes
Solution Approach 2:
The material layer deposited on the die surface serves as a temporary forming tool that can be removed after use. This approach replaces expensive, long-lead-time permanent dies with a reusable die surface that accepts temporary material layers, reducing both cost and lead time for complex part formation
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 to form sheet structures, enabling the creation of complex shapes with precision and efficiency, suitable for gas turbine engine components like aircraft exhaust ducts, while minimizing material costs and processing time.
Implementation Method 1
depositing at least one layer of material on the formation surface using a cold-spray deposition technique
Implementation Method 2
applying a releasing agent between the at least one layer of material and the formation surface
Implementation Method 3
etching the at least one layer of material from the formation surface using an acid or other chemically reactive material
Implementation Method 4
forming an interface coating on the formation surface via electroplating
Data Source
AI summary
A method for forming a sheet structure includes providing a tool having a formation surface corresponding to a shape of the sheet structure. The method also includes depositing at least one layer of material on the formation surface using a cold-spray deposition technique. The method also includes removing the at least one layer of material from the formation surface to create the sheet structure.