# US 11,441,227 B2 · Multi-wall deposited thin sheet structure

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- Number: US 11,441,227 B2
- Document ID: US11441227B2
- Status: Granted
- Kind: B2
- Application number: 16/706,083
- Filed: 2019-12-06
- Published: 2020-08-06
- Granted: 2022-09-13
- Earliest claimed: 2016-12-22
- Assignees: Raytheon Technologies Corporation
- Applicants: United Technologies Corporation
- Inventors: William J. Brindley; Gary D. Roberge
- Web page: https://patentgrep.com/patent/US11441227B2

## CPC

- C23C 24/04: Impact or kinetic deposition of particles
- B05D 1/02: performed by spraying
- C23C 24/08: by application of heat or pressure and heat (C23C24/04 takes precedence)
- F01D 5/288: {Protective coatings for blades}
- B05D 1/36: Successively applying liquids or other fluent materials, e.g. without intermediate treatment
- F01D 5/14: Form or construction (selecting particular materials, measures against erosion or corrosion F01D5/28)
- F01D 5/18: Hollow blades, {i.e. blades with cooling or heating channels or cavities (structure of hollow blades in general F01D5/147)}; Heating, heat-insulating or cooling means on blades
- F05D 2230/31: Layer deposition
- F05D 2230/90: Coating; Surface treatment
- F05D 2260/202: by film cooling
- F05D 2260/204: by the use of microcircuits
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS

## Abstract

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.

## Claims

### Claim 1

A system for forming a metallic structure having multiple layers, comprising:
a main tool having a main formation surface corresponding to a desired shape of a first layer of material;
a secondary tool having a second formation surface and configured to be positioned in a portion of a first volume defined by a first surface of the first layer of material;
a cold-spray gun configured to output a gas including particles of a material towards the main formation surface and the second formation surface at a velocity sufficiently great to cause the particles of the material to bond together on the main formation surface of the main tool to form the first layer of material and on the second formation surface of the secondary tool to form a second layer of material; and
a device for separating the main tool and the secondary tool from the first layer of material and the second layer of material to form the metallic structure having the first volume positioned between the first layer of material and the second layer of material.

### Claim 2 (depends on 1)

The system of claim 1, further comprising a computer configured to generate a model of at least one of the main tool or the secondary tool.

### Claim 3 (depends on 2)

The system of claim 2, further comprising an additive manufacturing machine configured to be controlled to form at least one of the main tool or the secondary tool using the additive manufacturing machine based on the model.

### Claim 4 (depends on 1)

The system of claim 1, wherein the device for separating the main tool and the secondary tool from the first layer of material and the second layer of material includes at least one of a mechanical tool usable to pry the material from a formation surface, a releasing agent configured to be applied between the material and the formation surface to separate the material from the formation surface, a heater configured to heat the formation surface to a sufficient temperature to separate the material from the formation surface, or an acid configured to be applied to at least one of the material or the formation surface to etch the material from the formation surface.