Cold Spray Reinforcement in Superplastic Formed Diffusion-Bonded Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing complex multi-curvature parts, such as superplastic forming with diffusion bonding, face challenges in controlling thickness, leading to undesirable step functions, increased weight, and limited configuration options due to the need for multiple components and processes.
Innovation Solution
The integration of cold spray additive manufacturing (CSAM) and superplastic formation diffusion bonding (SPFDB) components with a mold having a concavity, allowing for targeted thickness reinforcement and tapered edges, enabling the creation of complex structures with tailored thickness distribution and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If superplastic forming with welded sheets is used to increase part thickness for structural reinforcement, then structural strength is improved, but weight increases beyond what is necessary and configuration options are limited
Solution Approach 1:
The patent applies local quality by using cold spray additive manufacturing to deposit material only in specific target regions where thickness reinforcement is needed, rather than uniformly increasing thickness across the entire part. This allows structural reinforcement to be concentrated in high-stress areas while maintaining thin walls in non-critical regions, thereby improving strength where needed without unnecessarily increasing overall weight.
Solution Approach 2:
The patent employs preliminary action by depositing additive material onto the workpiece before performing superplastic forming. This pre-deposition ensures that the reinforcement material is in place to withstand the forming pressures and will be properly incorporated into the final part structure, rather than attempting to add material after forming when access would be limited.
2Strength
If multiple welded sheets are used to incrementally increase thickness, then structural reinforcement is achieved, but device complexity and fabrication time increase
Solution Approach 1:
The patent merges two previously separate processes into an integrated workflow: cold spray additive manufacturing is combined with superplastic forming diffusion bonding. By depositing additive material directly onto the workpiece and then performing SPFDB in the same manufacturing sequence, the patent eliminates the need for multiple separate welding operations and assembly steps, thereby reducing fabrication complexity while maintaining structural reinforcement benefits.
Solution Approach 2:
The patent uses preliminary action by pre-depositing the additive material onto the workpiece surface before the superplastic forming operation. This ensures that reinforcement features are already in place to withstand the forming pressures and will be properly incorporated into the final monolithic structure, eliminating the need for subsequent welding or assembly operations to add thickness.
3Strength
If additive sheets are used for thickness reinforcement, then structural strength is improved, but abrupt termination at sheet edges creates undesirable step functions in thickness
Solution Approach 1:
The patent applies dynamics by using a programmable deposition process that can dynamically adjust material placement. The cold spray system can vary deposition parameters in real-time to create gradual thickness transitions rather than abrupt changes, allowing the reinforced regions to blend smoothly into surrounding areas and eliminating step functions in the final part geometry.
Solution Approach 2:
The patent uses local quality by precisely controlling where additive material is deposited and in what quantity. The system can create varying thickness profiles within the target region, with gradual transitions at the boundaries, rather than applying uniform thickness increments that would create sharp edges and step functions in the final part geometry.
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 simplifies the manufacture of complex structures by providing structural reinforcement with tailored thickness, reducing weight and cost, and enabling the fabrication of parts with optimized weight and shape while handling structural stresses effectively.
Implementation Method 1
cold spray (with the CSAM component) an additive material onto the workpiece
Implementation Method 2
perform superplastic forming (with the SPFDB component) on the workpiece with the mold
Implementation Method 3
superplastic formation diffusion bonding
Data Source
AI summary
Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.