Cold Sprayed Composite Structures for Weight Reduction

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Solution Overview

Problem

Existing methods for forming composite components, such as those used in gas turbine engines, face challenges in reducing manufacturing costs and increasing efficiency while maintaining desirable mechanical and chemical properties, often requiring high-density, high-melting-point materials that are expensive and heavy.

Innovation Solution

The method involves forming a substrate from a first material and using cold spraying to attach a second material, which can be of different or same composition, accelerating particles of the second material onto the substrate surface without melting, to create features like bosses, baffles, and flanges, optimizing material selection for mechanical and chemical properties and reducing weight and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high-density, high-melting-point materials are used for all components, then mechanical strength and temperature resistance are improved, but weight and manufacturing cost increase

Engineering Contradiction:

Improvemechanical strengthVSAvoidcomponent weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies different material densities to different regions of the component based on local stress requirements. High-density materials are applied only to areas requiring high strength, while lower-density materials are used in less stressed regions, achieving optimal strength-to-weight ratio through spatially differentiated material properties.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates composite structures by combining multiple materials with different densities and properties in a single component. This allows the component to exhibit both high strength (from high-density material regions) and reduced weight (from lower-density material regions), resolving the contradiction between strength and weight.

Inventive Principle:

Principle #40Composite materials

2Strength

If high-density, high-melting-point materials are used for all components, then mechanical strength and temperature resistance are improved, but manufacturing cost increases

Engineering Contradiction:

Improvemechanical strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent reduces manufacturing cost by applying expensive high-density materials only where mechanically necessary, rather than uniformly throughout the entire component. This localized material application strategy maintains required strength while significantly reducing overall material cost.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite material construction to balance performance and cost. By combining high-density and lower-density materials, the component achieves the necessary mechanical strength at a lower overall material cost compared to using high-density material throughout.

Inventive Principle:

Principle #40Composite materials

3Reliability

If traditional manufacturing methods are used, then structural integrity is maintained, but manufacturing efficiency and cost reduction are limited

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges multiple manufacturing steps into a single additive manufacturing process. Features that would traditionally require separate casting, machining, and assembly operations are integrated into one additive manufacturing operation, significantly improving manufacturing efficiency while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the manufacturing approach from subtractive or formative methods to additive manufacturing. This parameter change in the manufacturing process enables complex geometries and multi-material construction without compromising structural integrity, while dramatically improving manufacturing efficiency.

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 manufacturing costs and increases efficiency by allowing the use of lower-density materials for less stressed components and higher-density materials for stressed areas, resulting in lighter and more cost-effective composite components with improved properties.

Implementation Method 1

cold spraying a second material that includes a metal or alloy on to at least a portion of the surface of the substrate to form at least one feature. The cold spraying includes accelerating particles of the second material toward the surface without melting the particles.

Methodology Applied

Scientific EffectCold spray:

Implementation Method 2

accelerating particles of the second material toward the surface without melting the particles

Methodology Applied

Scientific EffectParticle acceleration:

Data Source

PatentUS11426794B2Composite structures including multiple materials formed using cold spraying

Publication Date: 2022.08.30 ROLLS ROYCE CORP

AI summary

A composite component may include a substrate including a first material and defining a surface; and at least one feature attached to the surface of the substrate. The at least one feature may include a second, different material attached to the surface using cold spraying. Cold spraying may include accelerating particles of the second material toward the surface without melting the particles.