Cold Spray Thickness Tailoring in Superplastic Formed Metal Parts
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Solution Overview
Problem
Current methods for manufacturing complex multi-curvature parts, such as superplastic forming, 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, which result in higher costs and complexity.
Innovation Solution
The integration of cold spray additive manufacturing (CSAM) and superplastic formation diffusion bonding (SPFDB) techniques allows for targeted thickness reinforcement in metal workpieces, enabling tapered edges and functionally graded materials, reducing weight and cost by tailoring thickness profiles and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If superplastic forming is used to manufacture complex multi-curvature parts, then the shaped portion conforms to the desired complex geometry, but the thickness control becomes difficult resulting in thin areas and undesirable step functions
Solution Approach 1:
The patent applies preliminary action by depositing additive material onto the workpiece before performing superplastic forming. This pre-positioning of material ensures that thickness requirements are met before the forming process begins, preventing thin areas and step functions in the final product while still achieving complex multi-curvature geometry
Solution Approach 2:
The patent implements local quality by selectively depositing additive material only in specific target regions where thickness reinforcement is needed. This localized approach allows different parts of the workpiece to have different thickness characteristics, maintaining complex shape conformity while achieving precise thickness control in critical areas
2Strength
If welded sheets are used to increase part thickness for reinforcement, then structural strength is improved, but the incremental thickness is limited by available sheet thickness resulting in excessive weight
Solution Approach 1:
The patent applies local quality by selectively reinforcing only the specific target regions that require structural strength, rather than uniformly increasing thickness throughout the entire part. The additive material is deposited precisely where needed, providing structural reinforcement while minimizing unnecessary weight addition in non-critical areas
Solution Approach 2:
The patent implements parameter changes by enabling continuous thickness adjustment through controlled additive material deposition. Unlike discrete sheet welding that provides fixed thickness increments, the additive process allows precise control of thickness parameters, achieving the minimum required reinforcement without excessive material and weight
3Adaptability or versatility
If multiple components and processes are integrated to manufacture complex parts, then configuration options are increased, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies merging by combining the superplastic forming process with additive material deposition into a single integrated manufacturing process. Instead of using multiple separate components and processes, the additive process is integrated directly into the forming operation, reducing manufacturing complexity and cost while maintaining the ability to produce complex multi-curvature parts with optimized thickness profiles
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 enables the fabrication of complex structures with optimized weight and shape, improved structural performance, and reduced fabrication steps, resulting in lower weight and cost while handling structural stresses effectively.
Implementation Method 1
cold spray additive manufacturing (CSAM) component... 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, thereby rendering the workpiece into the finished workpiece having the shaped portion
Implementation Method 3
superplastic formation diffusion bonding (SPFDB) component... perform superplastic forming (with the SPFDB component) on the workpiece with the mold
Data Source
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AI summary
Examples are provided for fabricating a finished workpiece (120) having a shaped portion. One example includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold (150) having a concavity (152). Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An example is configured to cold spray (with the CSAM component) an additive material onto the workpiece (110); and perform superplastic forming (with the SPFDB component) on the workpiece (110) with the mold (150), thereby rendering the workpiece into the finished workpiece (120) having the shaped portion (122). 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 (124), 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.