US Patent Application 18363890. SYSTEMS AND METHODS FOR COLD SPRAY ADDITIVE MANUFACTURE WITH SUPERPLASTIC FORMATION DIFFUSION BONDING simplified abstract

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SYSTEMS AND METHODS FOR COLD SPRAY ADDITIVE MANUFACTURE WITH SUPERPLASTIC FORMATION DIFFUSION BONDING

Organization Name

The Boeing Company

Inventor(s)

Bruno Zamorano Senderos of Huntsville AL (US)

Dennis Lynn Coad of Madison AL (US)

Daniel G. Sanders of Lake Tapps WA (US)

SYSTEMS AND METHODS FOR COLD SPRAY ADDITIVE MANUFACTURE WITH SUPERPLASTIC FORMATION DIFFUSION BONDING - A simplified explanation of the abstract

This abstract first appeared for US patent application 18363890 titled 'SYSTEMS AND METHODS FOR COLD SPRAY ADDITIVE MANUFACTURE WITH SUPERPLASTIC FORMATION DIFFUSION BONDING

Simplified Explanation

This patent application describes a method for fabricating a finished workpiece with a shaped portion using superplastic formation diffusion bonding (SPFDB) and cold spray additive manufacturing (CSAM).

  • The method involves using a mold with a concavity to shape the workpiece.
  • The workpiece is first cold sprayed with an additive material using the CSAM component.
  • Then, superplastic forming is performed on the workpiece using the SPFDB component and the mold, resulting in the desired shape.
  • The cold spraying process increases the thickness of the finished workpiece in a specific region, providing structural reinforcement.
  • The increased thickness can also create a tapered edge in the shaped portion.
  • The workpiece can be made of various materials, such as titanium, aluminum, stainless steel, or others.


Original Abstract Submitted

Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and 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. 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, 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.

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