Modular Cold-Spray Tooling for Complex Sheet Structures
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Solution Overview
Problem
Conventional methods for forming sheet structures in gas turbine engines are expensive and time-consuming, especially for complex shapes, due to the high cost and complexity of die formation.
Innovation Solution
A method using a modular tool with interlocking features and a cold-spray technique, where the tool portions are coupled using dovetail features and materials with varying compressive yield strengths, allowing for efficient deposition and separation of material layers at an angle perpendicular to the formation surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional hot or cold forming using dies is used to form sheet structures, then the sheet structures can be formed with complex contours and size, but the cost and time required for die formation increases significantly
Solution Approach 1:
The tool is divided into multiple tool portions (first tool portion, second tool portion, etc.) that can be separately manufactured and then assembled together. This segmentation allows each portion to be produced more easily and at lower cost, while the assembled tool can still form complex sheet structure contours through the combined action of multiple portions with different formation surfaces.
2Strength
If conventional dies with durable material are used to withstand temperature and pressure loads, then the dies can maintain structural integrity, but the material cost and formation time increase
Solution Approach 1:
Different tool portions are made from materials with different compressive yield strengths based on their specific functional requirements. For example, tool portions subjected to higher loads use materials with greater compressive yield strength, while other portions use materials with lower compressive yield strength. This local differentiation allows the overall tool to maintain necessary structural integrity while reducing total material cost compared to using uniformly high-strength material throughout.
3Strength
If a single monolithic tool is used for cold-spray deposition, then the tool can maintain structural integrity under deposition loads, but the manufacturing complexity and cost increase for complex shapes
Solution Approach 1:
The tool is segmented into multiple tool portions that are coupled together using coupling members. Each tool portion can be manufactured separately with simpler geometry, avoiding the complexity of forming a single monolithic tool with complex contours. The coupling members connect these portions to create an assembled tool structure that maintains structural integrity during cold-spray deposition while reducing the manufacturing complexity of individual components.
Solution Approach 2:
The tool is constructed as a composite structure combining multiple tool portions made from different materials with varying compressive yield strengths. This composite construction allows each portion to be optimized for its specific loading conditions and manufacturing constraints, while the assembled tool provides the overall structural integrity needed for cold-spray deposition. The different materials are selected based on local requirements rather than using a single material throughout.
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 for forming sheet structures by using lower-cost materials and additive manufacturing, enabling the creation of complex shapes with improved efficiency and accuracy.
Implementation Method 1
depositing at least one layer of material on the main formation surface using a cold-spray technique
Implementation Method 2
cold-spray technique by forming a modular tool having a formation surface for receiving deposited material
Data Source
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AI summary
A method for forming a sheet structure (401; 501) includes depositing at least one layer of material (318; 408; 508) on a main formation surface (402; 502; 712; 801; 901) of a main tool (308; 400; 500; 700; 800; 900) using a cold-spray technique, the main tool having a plurality of tool portions (702; 802; 902; 904; 906) that each have a formation surface such that the formation surface of each of the plurality of tool portions (702; 802; 902; 904; 906) forms the main formation surface (402; 502; 712; 801; 901) corresponding to a desired structure shape of the sheet structure. The method also includes removing the at least one layer of material (318; 408; 508) from the main formation surface (402; 502; 712; 801; 901) to create the sheet structure.