Multi-Wall Thin Sheet Structure via Cold-Spray Deposition
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Solution Overview
Problem
Conventional methods for manufacturing sheet structures in gas turbine engines are expensive and time-consuming, particularly due to the costly and labor-intensive process of forming dies for complex shapes and sizes.
Innovation Solution
A method and system utilizing cold-spray deposition techniques to form metallic structures with multiple layers and volumes, where tools are created using additive manufacturing and interface coatings to efficiently deposit and separate layers, reducing material costs and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hot or cold forming using dies is used to manufacture sheet structures, then the structural integrity and shape accuracy are improved, but the manufacturing cost and time consumption increase significantly
Solution Approach 1:
The sheet structure is divided into multiple layers (first layer, second layer, third layer) that are formed separately using different tools (main tool, secondary tool, tertiary tool). Each layer can be manufactured independently, allowing parallel production and reducing the complexity of creating a single complex die for the entire multi-chamber structure.
Solution Approach 2:
The secondary tool and tertiary tool are positioned within volumes defined by previously deposited layers. The tools are nested within the structure being built, allowing sequential deposition of layers to form multi-walled structures with internal volumes, eliminating the need for complex multi-cavity dies.
2Manufacturing precision
If conventional hot or cold forming using dies is used to manufacture sheet structures, then the structural integrity and shape accuracy are improved, but the production time increases due to the time-consuming die formation process
Solution Approach 1:
Tools are prepared in advance using additive manufacturing technology, which allows rapid prototyping and customization of tooling. The main tool, secondary tool, and tertiary tool can be manufactured quickly with complex geometries, eliminating the time-consuming traditional die formation process while maintaining the ability to produce accurate sheet structures.
Solution Approach 2:
The traditional mechanical die forming process is replaced with cold-spray deposition technology. Instead of forcing material through complex dies under high pressure, material is deposited layer by layer in a controlled manner, enabling multi-layer structures to be built up sequentially without requiring complex multi-cavity dies, thus reducing both die formation time and actual production time.
3Adaptability or versatility
If complex dies with multiple cavities are used to form multi-layer sheet structures, then the manufacturing capability is improved, but the die complexity and cost increase
Solution Approach 1:
The manufacturing process transitions from a static multi-cavity die to a dynamic sequential deposition process. The main tool, secondary tool, and tertiary tool are positioned and removed in sequence, allowing flexible formation of different layer configurations. This dynamic approach enables the same equipment to produce various multi-layer structures without requiring complex fixed multi-cavity dies.
Solution Approach 2:
The cold-spray deposition process acts as an intermediary between the simple tools and the complex multi-layer structure. The deposition process builds up material layer by layer, creating complex geometries and multi-walled structures using relatively simple tools, thereby reducing die complexity while maintaining manufacturing capability.
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 cost-effective and time-efficient production of complex sheet structures with multiple layers and volumes, suitable for gas turbine engines, by using cold-spray deposition to form metallic structures with reduced material costs and processing time.
Implementation Method 1
depositing the first layer of material on the main formation surface using a cold-spray deposition technique
Implementation Method 2
depositing material onto a tool by propelling the material towards the tool at a velocity sufficiently great to cause the material to bond together on the tool
Data Source
AI summary
A method for forming a metallic structure having multiple layers includes providing a main tool having a main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing the first layer of material on the main formation surface using a cold-spray deposition technique. The method also includes positioning a secondary tool having a secondary formation surface in a portion of a first volume defined by a first surface of the first layer of material. The method also includes depositing a second layer of material on the secondary formation surface using the cold-spray deposition technique. The method also includes removing the secondary tool such that the first volume is positioned between the first layer of material and the second layer of material.