Lightweight Metallic Foam Core with External Shell
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Solution Overview
Problem
Existing methods for manufacturing components often compromise on weight, cost, or time due to the monolithic nature of raw materials, making it challenging to achieve low-cost, lightweight components that meet performance criteria.
Innovation Solution
A method involving a metallic foam core machined to a desired configuration, followed by the application of a ceramic-based thermal barrier coating and an external metallic shell using various deposition processes, allowing for localized structural rigidity and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If subtractive manufacturing or machining oversized blocks is used to achieve desired final part shape, then manufacturing precision can be achieved, but component weight increases and material waste occurs
Solution Approach 1:
The component is divided into two distinct parts: a metallic foam core that provides the base shape and an external metallic shell that provides the final precise dimensions and surface quality. This segmentation allows each part to be optimized independently - the foam core for weight reduction and the shell for precision.
Solution Approach 2:
The invention uses a composite structure combining metallic foam material with a metallic shell coating. This composite approach allows the component to benefit from both materials - the low density of foam and the high strength/precision of metal shell - resolving the contradiction between weight and manufacturing precision.
2Manufacturing precision
If subtractive manufacturing is used to achieve desired final part shape, then manufacturing precision can be achieved, but manufacturing cost increases due to material waste
Solution Approach 1:
By segmenting the manufacturing process into foam core formation followed by shell deposition, the invention eliminates the need to machine away large amounts of expensive material. The foam core is formed additively or from pre-formed blocks, and the shell is deposited only where needed, dramatically reducing material waste and manufacturing cost.
Solution Approach 2:
The invention changes the manufacturing parameter from subtractive (machining) to additive (deposition). Instead of removing material to achieve the final shape, the shell is built up on the foam core, which is more cost-effective and reduces material waste.
3Ease of manufacture
If uniform thickness of external metallic shell is applied, then manufacturing simplicity is maintained, but localized structural rigidity requirements cannot be met
Solution Approach 1:
The external metallic shell is applied with variable thickness rather than uniform thickness. This allows the shell to be thicker in areas requiring higher structural rigidity and strength, and thinner in areas where less support is needed, optimizing both strength and weight while maintaining manufacturing feasibility through controlled deposition processes.
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 results in lightweight, cost-effective components with enhanced structural rigidity and reduced raw material waste, achieving performance criteria while minimizing manufacturing time and cost.
Implementation Method 1
the interim coat is a ceramic based thermal barrier coating
Implementation Method 2
applying an external metallic shell to an exterior surface of the metallic foam core... wherein the external metallic shell is applied via an application process selected from the group comprising: flame spray application process
Implementation Method 3
applying an external metallic shell to an exterior surface of the metallic foam core... wherein the external metallic shell is applied via an application process selected from the group comprising: plasma spray application process
Implementation Method 4
applying an external metallic shell to an exterior surface of the metallic foam core... wherein the external metallic shell is applied via an application process selected from the group comprising: cold-spray application process
Implementation Method 5
applying an external metallic shell to an exterior surface of the metallic foam core... wherein the external metallic shell is applied via an application process selected from the group comprising: electron beam physical vapor deposition (EB/PVD) application process
Implementation Method 6
applying an external metallic shell to an exterior surface of the metallic foam core... wherein the external metallic shell is applied via an application process selected from the group comprising: chemical vapor deposition (CVD) application process
Implementation Method 7
applying an external metallic shell to an exterior surface of the metallic foam core... wherein the external metallic shell is applied via an application process selected from the group comprising: electroplating application process
Data Source
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AI summary
A method of making a light weight component (28) is provided. The method including the steps of: forming a metallic foam core (11) into a desired configuration; and applying an external metallic shell (20) to an exterior surface of the metallic foam core after it has been formed into the desired configuration.