Leading-edge structures for airfoils and systems and methods for fabricating the same

A method for fabricating a cold spray additively manufactured structure, the method comprising:

• cold spraying a metallic powder at a first velocity and at a first density on a tool surface to form an inner layer of a structure;
• cold spraying the metallic powder at a second velocity, which is greater than the first velocity, and at a second density, which is greater than the first density, on the inner layer to form a number of intermediate layers of the structure;
• and
• cold spraying the metallic powder a third velocity and at a third density, which is greater than the second density, on an outermost one of the intermediate layers to form an outer layer of the structure,
• wherein:
• the first velocity is below a level of permanent adhesion of the metallic powder to the tool surface;
• the second velocity is above a level of permanent adhesion of the metallic powder to the inner layer and any one of the intermediate layers;
• and
• the third velocity is above a level of permanent adhesion of the metallic powder to the outermost one of the intermediate layers.

A structure comprising:

• an inner layer formed by cold spray depositing a metallic powder at a first velocity and at a first density on a tool surface;
• a number of intermediate layers formed by cold spray depositing the metallic powder at a second velocity, which is greater than the first velocity, and at a second density, which is greater than the first density, on the inner layer;
• and
• an outer layer formed by cold spray depositing the metallic powder a third velocity and at a third density, which is greater than the second density, on an outermost one of the intermediate layers, opposite the inner layer,
• wherein:
• the first velocity is below a level of permanent adhesion of the metallic powder to the tool surface;
• the second velocity is above a level of permanent adhesion of the metallic powder to the inner layer and any one of the intermediate layers;
• and
• the third velocity is above a level of permanent adhesion of the metallic powder to the outermost one of the intermediate layers.