阅读说明：本技术 使用超塑性成形扩散粘结的冷喷涂增材制造的系统和方法 (System and method for cold spray additive manufacturing using superplastic forming diffusion bonding ) 是由 布鲁诺·萨莫拉诺·森德罗斯 丹尼斯·林恩·科德 丹尼尔·G·桑德斯 于 2021-06-01 设计创作，主要内容包括：本申请提供了使用超塑性成形扩散粘结的冷喷涂增材制造的系统和方法。本发明提供了用于制造具有成形部分的成品工件的实施方式。一个实施方式包括：超塑性成形扩散粘结(SPFDB)组件；冷喷涂增材制造(CSAM)组件；以及具有凹部的模具。可以使用SPFDB和CSAM组件以不同顺序在工件上操作各个配置。一个实施方式被配置为(用CSAM组件)将增材材料冷喷涂到工件上；并(用SPFDB组件)用模具在工件上进行超塑成形,从而将工件转化为具有成形部分的成品工件。成形部分符合由凹部限定的形状。冷喷涂使得目标区域中成品工件的厚度增加,其可以提供结构增强,并且其可以具有渐缩边缘。工件可以是由钛、铝、不锈钢或另一种材料制成的金属基板。(Systems and methods for cold spray additive manufacturing using superplastic forming diffusion bonding are provided. Embodiments are provided for manufacturing a finished workpiece having a shaped portion. One embodiment includes: superplastic forming diffusion bonded (SPFDB) components; cold Spray Additive Manufacturing (CSAM) components; and a mold having a recess. The various configurations may be operated on the workpiece in different sequences using SPFDB and CSAM components. One embodiment is configured to cold spray the additive material onto the workpiece (with the CSAM component); and superplastic forming (with the SPFDB assembly) the workpiece with a die to convert the workpiece into a finished workpiece having a formed part. The shaped portion conforms to a shape defined by the recess. Cold spraying increases the thickness of the finished workpiece in the target area, it may provide structural reinforcement, and it may have tapered edges. The workpiece may be a metal substrate made of titanium, aluminum, stainless steel, or another material.)

1. A system (100) for manufacturing a finished workpiece (120) having a shaped portion (122), the system (100) comprising:

superplastically forming a diffusion bonded assembly (400);

cold spray additive manufacturing components (300); and

a mold (150) having a recess (152);

wherein the system (100) is configured to:

-introducing an unfinished workpiece (110);

cold spraying an additive material (303) onto the unfinished workpiece (110) with the cold spray additive manufacturing assembly (300); and

superplastic forming with the superplastic forming diffusion bonding assembly (400) on the unfinished workpiece (110) with the die (150), thereby transforming the unfinished workpiece (110) into the finished workpiece (120) having the formed portion (122), the formed portion (122) conforming to a shape defined by the recess (152).

2. The system (100) of claim 1, wherein the unfinished workpiece (110) comprises a metal substrate having a metal selected from the list consisting of:

titanium, aluminum, and stainless steel.

3. The system (100) of claim 1, wherein the system (100) is configured to cold spray the additive material (303) such that a thickness of the finished workpiece (120) in a target area (124) is increased.

4. The system (100) according to claim 3, wherein the system (100) is configured to overlap at least a portion of the target region (124) with at least a portion of the shaped portion (122).

5. The system (100) of claim 3, wherein the system (100) is configured to provide structural reinforcement of the finished workpiece (120) in the target region (124) with increased thickness.

6. The system (100) of claim 3, wherein the system (100) is configured to taper the increased thickness of the finished workpiece (120) in the target region (124) at an edge (126) of the target region (124).

7. The system (100) of claim 1, wherein the system (100) is configured to double bend the shaped portion (122).

8. The system (100) of claim 1, wherein the cold spray additive manufacturing assembly (300) uses helium or nitrogen.

9. A method of manufacturing a finished workpiece (120) having a shaped portion (122), the method comprising:

cold spraying an additive material (303) onto an unfinished workpiece (110);

positioning the unfinished workpiece (110) on a mold (150) having a recess (152);

superplastically forming the unfinished workpiece (110) into a finished workpiece (120) having the shaped portion (122), the shaped portion (122) conforming to a shape defined by the recess (152); and

removing the finished workpiece (120) from the mold (150), wherein the cold spraying of the additive material (303) causes an increase in thickness of the finished workpiece (120) in a target area (124).

10. The method of claim 9, wherein the unfinished workpiece (110) comprises a metal substrate having a metal selected from the list consisting of:

titanium, aluminum, and stainless steel.

Technical Field

The present invention relates to the field of additive manufacturing, and in particular to a system and method for cold spray additive manufacturing using superplastic forming diffusion bonding.

Background

Manufacturing complex multi-curved parts (e.g., double-curved parts, such as orthogonally dimensioned curved parts) often requires integration of multiple components and processes. Typically, the surface is formed by superplastic forming (superplastic forming), hydroforming (hydroforming), incremental forming (incremental forming), or similar techniques. Unfortunately, superplastic forming can result in thin regions of the formed shape. Current methods place limitations on the shape and curvature of features that can be formed because it is often difficult to control the resulting thickness. For example, using superplastic forming diffusion bonding (SPFDB), weld plates are used in some locations to increase part thickness as reinforcement and resist thinning. However, the incremental thickness is a function of the plate thickness of the additive material available, which may be greater than necessary. This limits the configuration options and adds weight, beyond what is necessary if the thickness can be more finely adjusted.

Not only does the abrupt termination of the edge of the additive sheet create an undesirable step function in the thickness of the finished part, but the weld may have different superplastic behavior that limits the choice of reinforcements (e.g., location, size, and shape). Thus, incremental plate forming adds cost, complexity, manufacturing time, and may add weight beyond that required.

Disclosure of Invention

The disclosed embodiments are described in detail below with reference to the attached drawings, which are listed below. The following summary is provided to illustrate embodiments disclosed herein. However, it is not intended that all embodiments be limited to any particular configuration or order of operation.

Various embodiments are provided to manufacture a finished workpiece having a shaped portion. One embodiment includes: superplastic forming diffusion bonded (SPFDB) components; cold Spray Additive Manufacturing (CSAM) components; and a mold having a recess. The various configurations may be operated on the workpiece in different sequences using SPFDB and CSAM components. One embodiment is configured to cold spray the additive material onto the workpiece (with the CSAM component); and superplastic forming (with the SPFDB assembly) the workpiece with a die to convert the workpiece into a finished workpiece having a formed part. The shaped portion conforms to a shape defined by the recess. Cold spraying increases the thickness of the finished workpiece in the target area, it provides structural reinforcement, and it may have tapered edges (tapered edges). The workpiece may be a metal substrate made of titanium, aluminum, stainless steel, or another material.

The features, functions, and advantages that have been discussed are achieved independently in various embodiments or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

Drawings

The disclosed embodiments are described in detail below with reference to the attached drawings, which are listed below.

Fig. 1 shows a system for manufacturing a finished workpiece by performing Cold Spray Additive Manufacturing (CSAM) with superplastic forming diffusion bonding (SPFDB).

Fig. 2 illustrates various configurations of the system 100 of fig. 1.

FIG. 3 illustrates an implementation of an exemplary CSAM component that may be used in the system of FIG. 1.

Figure 4 illustrates an embodiment of an exemplary SPFDB component that may be used in the system of figure 1.

FIG. 5 illustrates stages of converting an unfinished workpiece (finished workpiece) into a finished workpiece (finished workpiece) using the configuration of the system shown in FIG. 2.

FIG. 6 is a flow chart illustrating a method of manufacturing a finished workpiece as shown at various stages of FIG. 5 using the configuration shown in FIG. 2.

Figure 7 illustrates stages in the conversion of an unfinished workpiece to a finished workpiece using another configuration of the system shown in figure 2.

FIG. 8 is a flow chart illustrating a method of manufacturing a finished workpiece as shown at various stages of FIG. 7 using the configuration shown in FIG. 2.

Figure 9 illustrates stages in the conversion of an unfinished workpiece to a finished workpiece using another configuration of the system shown in figure 2.

FIG. 10 is a flow chart illustrating a method of manufacturing a finished workpiece as shown at various stages of FIG. 9 using the configuration of the system shown in FIG. 2.

FIG. 11 illustrates stages of converting an unfinished workpiece to a finished workpiece using another configuration of the system shown in FIG. 2.

FIG. 12 is a flow chart illustrating a method of manufacturing a finished workpiece as shown at various stages of FIG. 11 using the configuration of the system shown in FIG. 2.

FIG. 13 is a flow chart illustrating another method of manufacturing a finished workpiece.

Figure 14 shows an arrangement for multi-sheet SPFDB formation of a sandwich structure with internal pockets.

Fig. 15 shows a four-piece sandwich structure.

Fig. 16 illustrates an option for forming a mat of additive material on at least some portions of the interior and/or exterior of a sandwich structure using CSAM.

Figure 17 is a flow diagram illustrating a method of manufacturing a sandwich structure using both SPFDB and CSAM.

FIG. 18 is a block diagram of a computing device suitable for implementing various aspects of the present disclosure.

FIG. 19 is a block diagram of a device production and service method that may employ aspects of the present disclosure.

FIG. 20 is a block diagram of a device that may employ aspects of the present disclosure.

Fig. 21 is a schematic perspective view of the particular heeling apparatus described with respect to fig. 20.

Corresponding reference characters indicate corresponding parts throughout the drawings.

Detailed Description

Various embodiments will be described in detail with reference to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. References and embodiments made throughout this disclosure in relation to particular embodiments are provided for illustrative purposes only, and are not meant to limit all embodiments unless indicated to the contrary.

The foregoing summary, as well as the following detailed description of certain embodiments, will be better understood when read in conjunction with the appended drawings. As used herein, an element or step recited in the singular and proceeded with the word "a" or "an" should be understood as not necessarily excluding plural elements or steps. Furthermore, references to "one implementation" or "an implementation" are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. Moreover, unless expressly stated to the contrary, embodiments "comprising" or "having" an element or a plurality of elements having a particular property may include additional elements not having that property.

Aspects of the present disclosure simplify the manufacture of complex structures using Cold Spray Additive Manufacturing (CSAM) in combination with superplastic forming diffusion bonding (SPFDB), for example by increasing the thickness of a finished workpiece (e.g., a metal sheet such as titanium, aluminum, or stainless steel) in a target area to provide structural reinforcement. By practicing one or more embodiments of the present disclosure, the increased thickness may be tapered at the edges, avoiding the disadvantages of step function differences in thickness (e.g., unnecessary weight, surface irregularities, and mechanical stress concentrations). In addition, the increased thickness can be adjusted to accommodate structural needs, eliminating the limitation of increasing the final workpiece thickness profile according to the thickness of the available material sheets. Some embodiments enable the manufacture of parts that are functionally graded enhanced by functionally grading the workpiece with dissimilar but compatible materials, for example by using CSAM and/or diffusion bonding. The result is improved component performance at lower weight and lower cost.

Aspects of the present disclosure reduce manufacturing steps, reduce costs, and improve supply chain operation. For example, complex structures made from multiple parts may be combined in a single manufacturing step. For example, the finished workpiece may be a single structure with integrated stiffeners, as in the prior art, either as separate components or added in a separate process. For example, stiffeners may be used in areas around fasteners and other high stress portions of the finished workpiece.

CSAM enhancement can produce SPFDB structures with higher complexity and superior tailored thickness profiles, such as thin walls where feasible and thicker walls where needed. This allows for better weight and shape while still handling structural stresses. SPFDB uses temperature and pressure profiling to deform a workpiece, which can thin areas of the workpiece. CSAM is used to apply thicker deposits in specific areas by building up a layer-by-layer deposit enhancing layer as the nozzle is moved repeatedly over the area, the number of passes and the speed of the passes determining the thickness of the built-up deposit. A number of different configurations are disclosed. Aspects of the present disclosure may be used in a multi-piece SPFDB to form a sandwich structure with an internal air pocket, for example, using four work piece pieces to form a 4-piece sandwich structure. CSAMs can be used to form a mat of additive material on at least some portions of the interior and/or exterior of the sandwich structure.

Aspects and embodiments disclosed herein relate to manufacturing a finished workpiece having a shaped portion. One embodiment includes: an SPFDB component; a CSAM component; and a mold having a recess. The various configurations may be operated on the workpiece in different sequences using SPFDB and CSAM components. One embodiment is configured to cold spray the additive material onto the workpiece (with the CSAM component); and superplastic forming (with the SPFDB assembly) the workpiece with a die to convert the workpiece into a finished workpiece having a formed part. The shaped portion conforms to the shape defined by the recess in some embodiments. Cold spraying increases the thickness of the finished workpiece in the target area, it may provide structural reinforcement, and it may have tapered edges. The workpiece may be a metal substrate made of titanium, aluminum, stainless steel, or another material.

Referring more particularly to the drawings, FIG. 1 shows a system 100 for fabricating a fabricated workpiece 120 by CSAM with SPFDB. The system 100 is a generic representation and a number of specific configuration variations are shown in fig. 2. The system 100 introduces (inter) an unfinished workpiece 110 and uses a mold (mold)150 (also spelled "mold" in some cases) to convert the unfinished workpiece 110 into a finished workpiece 120. In some embodiments, the unfinished workpiece 110 includes a metal substrate (e.g., a metal sheet) having a metal selected from the list consisting of titanium, aluminum, and stainless steel. Both the CSAM component 300 and the SPFDB component operate on the unfinished workpiece 110. The CSAM component 300 incorporates the CSAM material 301 and the SPFDB component 400 incorporates the SPFDB material 401.

The CSAM assembly 300 cold sprays the additive material 303 (from the CSAM material 301) onto the unfinished workpiece 110. The cold spray of the additive material 303 causes the thickness of the finished workpiece 120 to increase in the target area 124. This may provide structural reinforcement to the finished workpiece 120 in the target region 124, may provide a functionally graded material, and will be described in further detail with respect to fig. 3. The SPFDB assembly 400 is superplastically formed on the unfinished workpiece 110 using the die 150, as described in more detail with respect to fig. 4.

Turning next to FIG. 2, various configurations 200a-200d of the system 100 are shown. For configuration 200a, the CSAM assembly 300 sprays the additive material 303 onto the unfinished workpiece 110 in such a way that when the SPFDB assembly 400 forms the unfinished workpiece 110 into the shape of the finished workpiece 120 using the mold 150, the resulting finished workpiece 120 has a desired thickness profile. The stage of using the configuration 200a to change an unfinished workpiece 110 to a finished workpiece 120 is shown in fig. 5. For configuration 200b, the CSAM component 300 sprays the additive material 303 onto the mold 150, and then the SPFDB component 400 forms the unfinished workpiece 110 into the shape of the finished workpiece 120 using the mold 150 while diffusion bonding with the additive material 303 is performed. The resulting finished workpiece 120 has a desired thickness profile. The various stages of using the configuration 200b to change an unfinished workpiece 110 to a finished workpiece 120 are shown in FIG. 7.

For configuration 200c, the SPFDB component 400 forms the unfinished workpiece 110 into the rough shape of the finished workpiece 120 using the mold 150, and then the CSAM component 300 sprays an additive material 303 onto the unfinished workpiece 110 to convert it into the unfinished workpiece 120 having the desired thickness profile. Various stages of using the configuration 200c to change an unfinished workpiece 110 to a finished workpiece 120 are shown in FIG. 9. For configuration 200d, the CSAM component 300 sprays the additive material 303 onto the mold 150a (or mold 150), and then the SPFDB component 400 forms the unfinished workpiece 110 into the shape of the finished workpiece 120 using the mold 150a (or mold 150) while diffusion bonding it with the additive material 303. The resulting finished workpiece 120 has a desired thickness profile. The stages of using the configuration 200d to change an unfinished workpiece 110 to a finished workpiece 120 are shown in FIG. 11.

Fig. 3 illustrates an embodiment of a CSAM assembly 300 that includes a cold spray apparatus 302 that can be used to cold spray an additive material 303 onto an unfinished workpiece 110 to form a deposit 370. Additive material 303 may be in powder form of the same material as the unfinished workpiece (e.g., titanium or aluminum), or may be a different material for functional grading. A gas source 307, such as nitrogen or helium, is connected to the gas control module 306 through an inlet 308. The CSAM material 301 includes an additive material 303 and a gas 307. The gas control module 306 controls the flow of gas 307 through a first line 314 connected to the nozzle 304 and through a second line 316 connected to a powder chamber 318 and then to the nozzle 304. Gas 307 flowing through lines 314 and 316 causes additive material 303 located within powder chamber 318 to be ejected from nozzle 314 as particle stream 305. The particle stream 305 is conveyed at high velocity from the nozzle 304, the nozzle 304 may be a supersonic nozzle in one embodiment, and the particle stream 305 is deposited on the surface of the unfinished workpiece 110 to form the deposit 370. The particle stream 305 is ejected at a temperature well below the melting point of the additive material 303. Upon impact with the unfinished workpiece 110, the particles of the particle stream 305 undergo plastic deformation due to the high velocity of the particle stream 305 and bond to each other and to the unfinished workpiece 110 to increase the thickness of the unfinished workpiece 110.

In one embodiment, the cold spray apparatus 302 includes a heater 310 for heating the gas 307 to a desired temperature before the gas 307 enters the nozzle 304. For example, gas 307 may be heated to between 400 and 900 degrees celsius prior to entering nozzle 304 to eject additive material 303 as particle stream 305. The heater 310 is used to accelerate the velocity of the particle stream 305, but heat from the heated gas 307 is not transferred to the metallurgical bonding of the particles of the particle stream 305.

In one embodiment, the additive material 303 used in the cold spray process is configured to produce a desired thickness for the unfinished workpiece 110, as one of ordinary skill in the art having the benefit of this disclosure will recognize. Cold spraying of additive material 303, as opposed to thermal spraying, may allow for the use of large amounts of additive material 303 to produce a desired thickness. Additive material 303 may be a mixture of materials to produce structural reinforcement and other properties desired for the resultant workpiece 120. For example, additive material 303 may include nickel, cobalt, and iron powder. The use of cold spray helps to strengthen the finished workpiece 120, reducing distortion due to thermal and mechanical stresses.

In one embodiment, the CSAM assembly 300 includes a robotic control system 330 that controls a robotic positioning arm 332 to move the cold spray apparatus 302 relative to the unfinished workpiece 110. By moving the cold spray apparatus 302, the nozzle 304 is moved relative to the unfinished workpiece 110 such that the particle stream 305 produces a thinner or thicker portion of the deposit 370. For example, if the dwell time of the nozzle 304 is longer at the first position than at the second position, or the first position is traversed longer than the second position, the deposit 370 is thicker at the first position. In this manner, the deposit 370 may taper at its edges rather than having abrupt edges (e.g., step function edges). In one embodiment, the robotic positioning arm 332 moves the unfinished workpiece 110 instead of the cold spray apparatus 302. In one embodiment, the robotic positioning arm 332 moves both the unfinished workpiece 110 and the cold spray apparatus 302. In one implementation, the robotic control system 330 is controlled, at least in part, by one or more processors 1804 of the computing device 1800 of fig. 18 executing instructions. In one embodiment, robotic control system 330 includes an embodiment of computing device 1800. In one embodiment, the components of the cold spray apparatus 302 (e.g., the gas control module 306 and the heater 310) are controlled by an embodiment of the computing apparatus 1800.

Figure 4 illustrates an embodiment of an SPFDB assembly 400 that includes an SPFDB device 402 that may be used to perform superplastic forming to shape the unfinished workpiece 110 and diffusion bonding to bond the material to the unfinished workpiece 110. Specifically, the SPFDB device 402 shapes the unfinished workpiece 110 into the mold 150, which is shown with the recess 152. The lid 410 is placed over the forming chamber 412 to sandwich the unfinished workpiece 110 between the lid 410 and the forming chamber 412. The unfinished workpiece 110 is heated to a superplastic temperature using a heater 422.

The gas source 407 is connected to the gas control module 406 through an inlet 408. When the unfinished workpiece 110 has reached a superplastic temperature, a gas 407 (which may be dry argon) is injected under pressure through the inlet line 414 and the channel 418 in the lid 410 to pressurize the space between the underside of the lid 410 and the unfinished workpiece 110. The pressure of the gas 407 acting on the unfinished workpiece 110 deforms the unfinished workpiece 110 into the recess 152 of the mold 150. Pressure may be displaced from the forming chamber 412 through the second gas line 416 and the passage 420 in the forming chamber 412. When the unfinished workpiece 110 has finished conforming to the recess 152 of the mating mold 150, the forming pressure of the gas 407 is released and the lid 410 is released and removed from the forming chamber 412. In one embodiment, back pressure is applied (e.g., using gas 407) via the second gas line 416 and the channel 420.

The SPFDB material 401 comprises a release agent 403 and a gas 407. In one embodiment, a release agent 404 is applied to facilitate removal of the finished workpiece 120 (or unfinished workpiece 110, depending on whether SPFDB is the final process step) from the mold 150. In one embodiment, the SPFDB component 400 includes an embodiment of a computing device 1800 that controls components of the SPFDB device 402 (e.g., the gas control module 406 and the heater 422).

FIG. 5 illustrates stages 501-503 of changing an unfinished workpiece 110 to a finished workpiece 120 using the configuration 200a of the system 100 as shown in FIG. 2. The unfinished workpiece 110 has a front side 111 and a back side 112, the front side 111 being placed against the mold 150. The mold 150 has a recess 152. Although only a two-dimensional (2D) profile is shown, it should be understood that the recess 152 in the mold 150 may be doubly curved, i.e., curved in orthogonal dimensions. For example, the recess 152 shown in 2D is a semicircle in three dimensions (3D), which may be hemispherical. At stage 501, the unfinished workpiece 110 has not yet conformed to the recess 152 of the mating mold 150, nor has the unfinished workpiece 110 been cold spray coated.

At stage 502, additive material 303 is cold sprayed onto unfinished workpiece 110, forming deposits 370 in target region 124. It should be understood that the deposits 370 may be on one or both of the front side 111 and the back side 112 of the unfinished workpiece 110. As shown, the target area 124 spans a portion of the unfinished workpiece 110 that will conform to the recess 152 of the mold 150. At stage 503, the unfinished workpiece 110 has been reshaped by superplastic forming and has been converted to a finished workpiece 120 having a formed portion 122. As shown, the target area 124 spans the entire shaped portion 122, although it should be understood that this is for illustration purposes only. In some embodiments, at least a portion of the target region 124 overlaps at least a portion of the shaped portion 122 such that the shaped portion 122 may encompass the entire target region 124 and further extend beyond the target region 124, the target region 124 may span the entire shaped portion 122 and further extend beyond the shaped portion 122, and the target region 124 and the shaped portion 122 may partially overlap.

In one embodiment, the increased thickness left by the deposit 370 provides structural reinforcement of the finished workpiece 120 in the target region 124. Also, as shown, the increase in thickness of the finished workpiece 120 in the target region 124 tapers at the edge 126 of the target region 124. For illustrative purposes, an abrupt edge 128 that produces a step function in the thickness of the finished workpiece 120 is also shown. In one embodiment, the system 100 has the advantageous ability to avoid abrupt edges and produce tapered edges, which may be preferred in some circumstances.

FIG. 6 is a flow chart illustrating a method of manufacturing the finished workpiece 120 as shown in stages 501-503 of FIG. 5 using the configuration 200a of FIG. 2. Operation 602 includes receiving requirements for the finished workpiece 120, such as shape and thickness profile and material for use with the additive material 303. Operation 604 includes controlling the temperature of the unfinished workpiece 110, the gas 307, and the additive material 303. In one embodiment, the unfinished workpiece 110 includes a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel.

Operation 606 includes cold spraying additive material 303 onto unfinished workpiece 110. In one embodiment, the cold spray uses helium or nitrogen. Operation 608 includes positioning the unfinished workpiece 110 on the mold 150 having the recess 152. Operation 610 includes controlling the temperature of the unfinished workpiece 110, the mold 150, and the gas 407. Operation 612 includes superplastically forming the unfinished workpiece 110 into a finished workpiece 120 having a formed portion 122, the formed portion 122 conforming to a shape defined by the recess 152. Operation 614 includes removing the finished workpiece 120 from the mold 150. In one embodiment, removing the finished workpiece 120 from the mold 150 includes removing the finished workpiece 120 from the mold 150 using the release agent 403. In one embodiment, removing the finished workpiece 120 from the mold 150 includes using back pressure, for example, via the second gas line 416 and the channel 420.

Cold spraying the additive material 303 in operation 606 has caused the thickness of the finished workpiece 120 in the target region 124 to increase. In one embodiment, at least a portion of the target region 124 overlaps at least a portion of the shaped portion 122. In one embodiment, the increased thickness of the finished workpiece 120 in the target region 124 tapers at the edge 126 of the target region 124. In one embodiment, the shaped portion 122 is doubly curved. In one embodiment, the increased thickness provides structural reinforcement of the finished workpiece 120 in the target area 124.

FIG. 7 shows stages 701-703 for changing an unfinished workpiece 110 to a finished workpiece 120 using the configuration 200b of the system 100 as shown in FIG. 2. At stage 701, unfinished workpiece 110 has not conformed to recess 152 of mating mold 150, nor has unfinished workpiece 110 been cold sprayed. At stage 702, additive material 303 is cold sprayed onto mold 150, within recess 152, forming deposit 372. At stage 703, the unfinished workpiece 110 has been reshaped by superplastic forming and is thus converted into a finished workpiece 120 having a formed portion 122. As shown, the target zone 124 spans a portion of the shaped portion 122 corresponding to the location of the deposit 372. The additive material 303 of deposit 372 has diffusion bonded to the unfinished workpiece 110 (now finished workpiece 120). The location, thickness and edges of the target area 124 may be controlled as previously described.

FIG. 8 is a flow chart 800 illustrating a method of fabricating the finished workpiece 120 as shown in stages 701-703 of FIG. 7 using the configuration 200b of FIG. 2. Operation 802 includes receiving requirements for the finished workpiece 120, such as shape and thickness profile and material for use with the additive material 303. Operation 804 includes controlling the temperature of mold 150, gas 307, and additive material 303. Operation 806 includes cold spraying additive material 303 onto mold 150 having recess 152. In one embodiment, the cold spray uses helium or nitrogen.

Operation 808 includes positioning the unfinished workpiece 110 on the mold 150. In one embodiment, the unfinished workpiece 110 includes a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel. Operation 810 includes controlling the temperature of the unfinished workpiece 110, the mold 150, the deposit 372, and the gas 407. Operation 812 includes superplastically forming the unfinished workpiece 110 and diffusion bonding the cold sprayed additive material 303 (as deposit 372) with the unfinished workpiece 110, thereby transforming the unfinished workpiece 110 into a finished workpiece 120 having a formed portion 122, the formed portion 122 conforming to the shape defined by the recess 152. Operation 814 includes removing the finished workpiece 120 from the mold 150. In one embodiment, removing the finished workpiece 120 from the mold 150 includes removing the finished workpiece 120 from the mold 150 using the release agent 403. In one embodiment, removing the finished workpiece 120 from the mold 150 includes using back pressure, for example, via the second gas line 416 and the channel 420.

Cold spraying the additive material 303 in operation 806 increases the thickness of the finished workpiece 120 in the target region 124. In one embodiment, at least a portion of the target region 124 overlaps at least a portion of the shaped portion 122. In one embodiment, the increased thickness of the finished workpiece 120 in the target region 124 tapers at the edge 126 of the target region 124. In one embodiment, the shaped portion 122 is doubly curved. In one embodiment, the increased thickness provides structural reinforcement of the finished workpiece 120 in the target area 124.

FIG. 9 illustrates the stages of changing an unfinished workpiece 110 to a finished workpiece 120 using the configuration 200c of the system 100 shown in FIG. 2. At stage 901, unfinished workpiece 110 has not yet conformed to recess 152 of mating mold 150, nor has unfinished workpiece 110 been cold sprayed. At stage 902, the unfinished workpiece 110 is reshaped by superplastic forming to conform to the mold 150 and to have a formed portion 122. At stage 903, additive material 303 is cold sprayed onto unfinished workpiece 110 on the convex surface or the concave surface or both. The cold spray transforms the unfinished workpiece 110 into a finished workpiece 120. The location, thickness and edges of the target area 124 may be controlled as previously described.

FIG. 10 is a flow chart 1000 illustrating a method of manufacturing a finished workpiece 120 as shown at stage 901-903 of FIG. 9 using the configuration 200c of FIG. 2. Operation 1002 includes receiving requirements for the finished workpiece 120, such as shape and thickness profile and material for use with the additive material 303. Operation 1004 includes positioning the unfinished workpiece 110 on a mold 150 having a recess 152. In one embodiment, the unfinished workpiece 110 includes a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel. Operation 1006 includes controlling the temperature of the unfinished workpiece 110, the mold 150, and the gas 407.

Operation 1008 includes superplastically forming the unfinished workpiece 110 into a finished workpiece 120 having a formed portion 122, the formed portion 122 conforming to the shape defined by the recess 152. Operation 1010 includes removing the unfinished workpiece 110 from the mold 150. In one embodiment, removing the unfinished workpiece 110 from the mold 150 includes removing the unfinished workpiece 110 from the mold 150 using a release agent 403. In one embodiment, removing the unfinished workpiece 110 from the mold 150 includes using back pressure, for example, via the second gas line 416 and the channel 420.

Operation 1012 includes controlling the temperature of the unfinished workpiece 110, the gas 307, and the additive material 303. Operation 1014 includes cold spraying additive material 303 onto unfinished workpiece 110. In one embodiment, the cold spray uses helium or nitrogen. Cold spraying the additive material 303 in operation 1014 increases the thickness of the finished workpiece 120 in the target region 124. In one embodiment, at least a portion of the target region 124 overlaps at least a portion of the shaped portion 122. In one embodiment, the increased thickness of the finished workpiece 120 in the target region 124 tapers at the edge 126 of the target region 124. In one embodiment, the shaped portion 122 is doubly curved. In one embodiment, the increased thickness provides structural reinforcement of the finished workpiece 120 in the target area 124.

FIG. 11 illustrates the stages of changing an unfinished workpiece 110 to a finished workpiece 120 using the configuration 200d of the system 100 shown in FIG. 2. At stage 1101, the unfinished workpiece 110 has not been cold sprayed or superplastic formed. A mold 150a having a recess 152a is shown. Additive material 303 is cold sprayed onto mold 150a, within recess 152, forming deposit 376, although mold 150 may alternatively be used for this purpose. In addition, a die 150b having a recess 152b is shown that will be used to form the unfinished workpiece 110, although the die 150 may alternatively be used for this purpose.

At stage 1102, deposit 376 (including additive material 303) is transferred from mold 150a to mold 150 b. In one embodiment, recess 152a is shaped sufficiently similar to recess 152b to form deposit 372. In one embodiment, additive material 303 is cold sprayed directly onto mold 150b, rather than first onto mold 150a and then moved. In one embodiment, mold 150 is used instead of molds 150a and 150 b. In stage 1103, the unfinished workpiece 110 is reshaped by superplastic forming and diffusion bonded to deposit 376 at point 130. This converts the unfinished workpiece 110 into a finished workpiece 120 having a formed portion 122 (which in this case was previously a deposit 376). This results in the length 132 of the finished workpiece 120 being extended by the length 136 provided by the deposit 376 relative to the length 134 of the unfinished workpiece 110. The location, thickness and edges of the target area 124 may be controlled as previously described.

FIG. 12 is a flow chart 1200 illustrating a method of manufacturing a finished workpiece 120 as shown in stage 1101-1103 of FIG. 11 using the configuration 200d of FIG. 2. Operation 1202 includes receiving requirements for the finished workpiece 120, such as a shape and thickness profile and a material for use with the additive material 303. Operation 1204 comprises controlling the temperature of mold 150a, gas 307, and additive material 303. Operation 1206 includes cold spraying additive material 303 onto mold 150a having recess 152 a. In one embodiment, the cold spray uses helium or nitrogen.

Operation 1208 includes positioning the unfinished workpiece 110 on the mold 150b and placing the cold sprayed additive material 303 (e.g., deposit 376) on the mold 150 b. In one embodiment, placing cold sprayed additive material 303 on mold 150b includes placing cold sprayed additive material 303 in recess 152 b. In one embodiment, placing cold sprayed additive material 303 onto mold 150b includes cold spraying additive material 303 onto mold 150b (instead of mold 150 a). In one embodiment, the unfinished workpiece 110 includes a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel.

Operation 1210 includes controlling the temperature of the unfinished workpiece 110, the mold 150, the deposit 372, and the gas 407. Operation 1212 includes superplastically forming the unfinished workpiece 110 and diffusion bonding the cold sprayed additive material 303 (as deposit 376) with the unfinished workpiece 110 to transform the unfinished workpiece 110 into a finished workpiece 120 having a shaped portion 122, the shaped portion 122 conforming to a shape defined by the recess 152. Operation 1214 includes removing the finished workpiece 120 from the mold 150. In one embodiment, removing the finished workpiece 120 from the mold 150 includes the mold 150 removing the finished workpiece 120 from the mold 150 using the release agent 403. In one embodiment, removing the finished workpiece 120 from the mold 150 includes using back pressure, for example, via the second gas line 416 and the channel 420.

Cold spraying of additive material 303 in operation 1206 causes length 132 of finished workpiece 120 to be extended relative to length 134 of unfinished workpiece. In one embodiment, cold sprayed additive material 303 (e.g., deposit 376) tapers at its edges. In one embodiment, the shaped portion 122 is doubly curved. In one embodiment, the increased thickness provides structural reinforcement of the finished workpiece 120 in the target area 124.

FIG. 13 is a flow chart 1300 illustrating another method of manufacturing a finished workpiece 120. In one embodiment, operation 1302 includes receiving requirements for finished workpiece 120, such as shape and thickness profiles and materials used for additive material 303. In operation 1304, a particular configuration is selected, such as one of the configurations 200a-200d of the system 100. In operation 1306, components of the system 100, such as the CSAM component 300 and the SPFDB component 400, are configured according to the selection made in operation 1304. An unfinished workpiece 110 is received in operation 1308. As operation 1308, an appropriate one of the flow diagrams 600, 800, 1000, and 1200 is executed to manufacture a finished workpiece 120 (e.g., to convert an unfinished workpiece 110 to a finished workpiece 120).

Having thus described the various operations of the various configurations 200a-200d, and referring again to FIG. 1, the system 100 is a system for manufacturing a finished workpiece 120 having a shaped portion 122, the system 100 comprising: an SPFDB component 400; a CSAM component 300; and a mold 150 having a recess 152; wherein the system 100 is configured to: introducing an unfinished workpiece 110; cold spraying the additive material 303 onto the unfinished workpiece 110 with the CSAM assembly 300; and superplastic forming using the SPFDB assembly 400 on the unfinished workpiece 110 using the die 150 to convert the unfinished workpiece 110 into a finished workpiece 120 having a formed portion 122, the formed portion 122 conforming to a shape defined by the recess 152. In one embodiment, the unfinished workpiece 110 includes a metal substrate having a metal selected from the list consisting of titanium, aluminum, and stainless steel. In one embodiment, the cold spray of the additive material 303 causes the thickness of the finished workpiece 120 to increase in the target area 124. In one embodiment, at least a portion of the target region 124 overlaps at least a portion of the shaped portion 122. In one embodiment, the increased thickness provides structural reinforcement of the finished workpiece 120 in the target area 124. In one embodiment, the increased thickness of the finished workpiece 120 in the target region 124 tapers at the edge 128 of the target region 124. In one embodiment, the shaped portion 122 is doubly curved. In one embodiment, the cold spray uses helium or nitrogen. In one embodiment, removing the finished workpiece 120 from the mold 150 includes removing the finished workpiece 120 from the mold 150 using the release agent 403.

Figure 14 shows an arrangement 1400 for a multi-sheet SPFDB to form a sandwich structure 1402 with internal pockets 1404a-1404 d. Two workpieces, workpiece 110a and workpiece 110b, are joined by seams 1412a, 1412b, and 1412 c. The gas line 1410 provides pressure to inflate the inner pockets 1404a-1404d, thereby creating the sandwich 1402. In some embodiments, argon gas is used to minimize oxidation of the workpieces 110a and 110b, or other adverse interactions that may occur at temperatures required to superplastically form the workpieces 110a and 110b into the sandwich structure 1402.

Fig. 15 shows a 4-piece sandwich structure 1500 using a sandwich structure 1402 as a core. Sandwich structure 1500 has a face layer 1501 (made from work piece 110 c), a first core layer 1502 (made from work piece 110a of fig. 14), a second core layer 1503 (made from work piece 110b of fig. 14), and a second face layer 1504 (made from work piece 110 d). The sandwich structure 1500 may provide enhanced structural strength and noise reduction on a flat piece made of the same four pieces of material (without the inner pockets 1404a-1404 d). In some embodiments, second gas line 1510 is provided to expand region 1512 between core layers 1502 and 1503 and face layers 1501 and 1504 during an SPFDB process.

Fig. 16 shows an option for forming a pad of additive material 1602-1618 on at least some portions of the interior and/or exterior of sandwich structure 1500 using CSAM. The increased thickness of the additive material (e.g., additive material pad 1602-1618) provides structural reinforcement for sandwich structure 1500. For example, additive material pad 1602 is on the outside of face layer 1501 on at least a portion of the space between face layer 1501 and core layer 1502 where pockets (gaps) exist. This operation may be repeated for other pocket positions. Additive material pad 1604 is on the inside of face layer 1501 on at least a portion of the pocket between face layer 1501 and core layer 1502. This operation may be repeated for other pocket positions. Additive material pads 1606 are on the outside of face layer 1501 on at least a portion of the interface between face layer 1501 and core layer 1502 where diffusion bonding is present. This step may be repeated for other diffusion bonding locations. An additive material pad 1608 is on the inside of face layer 1501 on at least a portion of where there is a diffusion bond between face layer 1501 and core layer 1502. This step may be repeated for other diffusion bonding locations. The pad locations for face layer 1501 thus described may be replicated in the equivalent locations (relative to core layer 1503) for face layer 1504.

Additive material pad 1612 is on the outside (relative to sandwich structure 1402) of core layer 1503 on at least a portion of the pocket existing between surface layer 1504 and core layer 1503. This operation may be repeated for other pocket positions. Additive material pad 1614 is on the inside (relative to sandwich structure 1402) of core layer 1503 over at least a portion of the pocket existing between surface layer 1504 and core layer 1503. This operation may be repeated for other pocket positions. Additive material pad 1616 is on the outside of core layer 1503 on at least a portion of the portion between surface layer 1504 and core layer 1503 where a diffusion bond exists. This step may be repeated for other diffusion bonding locations. Additive material pad 1618 is on the inside of core layer 1503 on at least a portion of the portion between surface layer 1504 and core layer 1503 where a diffusion bond exists. This step may be repeated for other diffusion bonding locations. The pad locations for the facings 1504 so described may be replicated in equivalent locations for the facings 1501 (relative to the core layer 1502). Some pad locations may provide better performance than other pad locations. Furthermore, relative to other features shown in sandwich structure 1500, pads 1602-1618 of additive material may be wider or narrower than shown. Pads of additive material 1602-1618 represent all of the pads that can be replicated on sandwich structure 1500 in corresponding locations relative to the pockets and diffusion bonding locations.

Figure 17 is a flow diagram 1700 illustrating a method of manufacturing a sandwich structure 1500 using both SPFDB and CSAM. In operation 1702, CSAM is performed to form at least any one of the pads 1604, 1608, 1612, 1614, 1618, and 1618 of additive material to be masked after the SPFDB process of operation 1702. Thus, operation 1702 includes cold spraying an additive material onto at least one of the plurality of workpieces 110a-110d for use in a sandwich structure (e.g., sandwich structure 1402 or 1500). In one embodiment, the cold spray uses helium or nitrogen.

In one embodiment, the sandwich structure 1500 is formed in a single SPFDB operation 1704. In one embodiment, the sandwich structure 1402 is formed in a first SPFDB operation 1704, thereby allowing for the addition of pads 1612 and 1616 of additive material in a second pass operation 1702, and then the sandwich structure 1500 is formed using the sandwich structure 1402 in a second SPFDB operation 1704. Thus, operation 1704 includes superplastic forming and diffusion bonding the plurality of workpieces 110a-110d into the sandwich structure 1402 or 1500. In one embodiment, sandwich structure 1500 comprises a 4-piece sandwich structure.

In operation 1706, a CSAM process is performed on the formed sandwich structure 1500 to add the pads 1602 and 1606 of additive material, although the pads 1602 and 1606 of additive material may alternatively be formed in operation 1702. Operation 1702 is optional if only pads 1602 and 1606 of additive material (and other pads in corresponding locations) are used. Thus, although at least one of operations 1702 and 1706 should be performed, each of operations 1702 and 1706 is optional. Operation 1706 includes cold spraying the additive material onto a sandwich structure (e.g., sandwich structure 1500 formed in a single operation 1704 or a two pass operation 1704).

In this manner, aspects of the present disclosure may be used with a multi-piece SPFDB to form a sandwich structure with internal pockets, e.g., using four pieces of work to create a four-piece sandwich structure (e.g., sandwich structure 1500). CSAM may be used to form pads on at least some portions of the interior and/or exterior of sandwich structure 1500, such as on the interior or exterior of face layers 1501 and 1504 and/or on the interior or exterior of core layers 1502 and 1503.

Referring now to FIG. 18, there is depicted a block diagram of a computing device 1800 suitable for implementing various aspects of the present disclosure. In some implementations, the computing device 1800 includes one or more processors 1819 that execute an operating system 1820 and application software 1821 maintained in memory 1802. The disclosed embodiments associated with computing device 1800 are practiced with a variety of computing devices, including personal computers, laptops, smart phones, mobile tablets, handheld devices, consumer electronics, special purpose computing devices, and the like. No distinction is made between categories such as "workstation," server, "" laptop, "" handheld device, "etc., all of which are encompassed within the scope of fig. 18 and are referred to herein as" computing devices. The disclosed embodiments may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. Moreover, although the computing device 1800 is depicted as appearing to be a single device, in one embodiment, multiple computing devices work together and share the depicted device resources. For example, in one embodiment, the memory 1822 is distributed across multiple devices, one or more processors 1819 provided are housed on different devices, and so on.

In one implementation, the memory 1822 includes any of the computer-readable media described herein. In one embodiment, the memory 1822 is used to store and access instructions configured to perform the various operations disclosed herein. In some implementations, the memory 1822 includes computer storage media in the form of volatile and/or nonvolatile memory, removable or non-removable memory, a data disk in a virtual environment, or a combination thereof. In one embodiment, the one or more processors 1819 include any number of processing units that read data from various entities, such as memory 1822, communication interface 1823, or input/output (I/O) controller 1824. In particular, the one or more processors 1819 are programmed to execute computer-executable instructions for implementing aspects of the present disclosure. In one embodiment, the instructions are performed by multiple processors 1819 within computing device 1800, or by a processor 1819 external to computing device 1800.

Communication interface 1823 allows computing device 1800 to be logically coupled to other devices, which may be public or private and use various protocols, e.g., over a wired or wireless network. The I/O controller 1824 provides output 1825 and input 1826 that enable operation and control of the computing device 1800. Those skilled in the art will understand and appreciate that computer data is presented in a variety of ways, such as visually in a Graphical User Interface (GUI), audibly through a speaker, and wirelessly or across a wired connection to a peripheral device. Those skilled in the art will also understand and appreciate that computer input is received in a variety of ways, such as via a microphone, a keyboard or keypad, a mouse or other pointing device, and a touch screen. Although described in connection with computing device 1800, embodiments of the present disclosure are operational with numerous other general purpose or special purpose computing system environments, configurations or devices.

As shown and described with respect to fig. 19-21, some embodiments of the present disclosure are used in manufacturing and service applications. Thus, embodiments of the present disclosure are described in the context of apparatus 1900 of the manufacturing and service method shown in fig. 19 and apparatus 2000 shown in fig. 20. In FIG. 19, a block diagram illustrating a device manufacturing and service method 1900 is depicted, in accordance with one embodiment. In one embodiment, during pre-production, device manufacturing and service method 1900 includes specification and design 1902 of device 2000 in FIG. 20 and material procurement 1904. During production, component and subassembly fabrication 1906 and system integration 1908 of the device 2000 in fig. 20 occur. Thereafter, the device 2000 in fig. 20 passes authentication and delivery 1910 to be placed into service 1912. When serviced by a customer, the apparatus 2000 in FIG. 20 performs routine maintenance and repair 1914 as scheduled, which in one embodiment includes modifications, reconfigurations, refurbishments, and other maintenance and repair for configuration management as described herein.

In one embodiment, each of the processes of device manufacturing and service method 1900 is performed or carried out by a system integrator, a third party, and/or an operator. In these embodiments, the operator is a customer. For purposes of this description, a system integrator includes a number of device manufacturers and major-system subcontractors; third parties include many orderers, subcontractors and suppliers; and in one embodiment, the operator is an owner of the equipment or fleet of equipment, an administrator responsible for the equipment or fleet of equipment, a user operating the equipment, a leasing company, a military entity, a service organization, and the like.

Referring now to fig. 20, an apparatus 2000 is depicted. As shown in fig. 20, an embodiment of the device 2000 is a flying device 2001, such as an aerospace vehicle, an airplane, air cargo, a flying automobile, and the like. Also shown in fig. 20, another embodiment of the apparatus 2000 is a ground transportation apparatus 2002, such as an automobile, truck, heavy equipment, construction equipment, boat, ship, submarine, or the like. A further embodiment of the device 2000 shown in fig. 20 is a modular device 2003, which comprises at least one or more of the following modules: an air module, a payload module, and a ground module. The air module provides air lift or flight capability. The payload module provides the ability to transport objects such as cargo or living objects (humans, animals, etc.). The ground module provides ground movement capability. The solution disclosed herein is applied to each module, such as air and payload modules, or payload and ground modules, etc., or all modules, individually or in groups.

Referring now to fig. 21, a more specific diagram of a flying apparatus 2001 is depicted in which embodiments of the present disclosure are advantageously employed. In this embodiment, flying equipment 2001 is an aircraft produced by equipment manufacturing and service method 1900 of fig. 19 and includes a fuselage 2102 having a plurality of systems 2104 and an interior 2106. Embodiments of the plurality of systems 2104 include one or more of a propulsion system 2108, an electrical system 2110, a hydraulic system 2112, and an environmental system 2114. However, other systems are also included candidates. Although an aerospace embodiment is shown, the different advantageous embodiments apply to other industries, such as the automotive industry, and the like.

Embodiments disclosed herein are described in the general context of computer code or machine-useable instructions, including computer-executable instructions (e.g., program components) that are executed by a computer or other machine (e.g., a personal data assistant or other handheld device). Generally, program components including routines, programs, objects, components, data structures, etc., refer to code that performs particular tasks or implements particular abstract data types. The disclosed embodiments are practiced in various system configurations, including personal computers, laptops, smart phones, mobile tablets, handheld devices, consumer electronics, specialized computing devices, and the like. The disclosed embodiments may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network.

The following paragraphs describe other aspects of the disclosure:

A1. a system for manufacturing a finished workpiece having a shaped portion, the system comprising: a superplastic forming diffusion bonding (SPFDB) component;

cold Spray Additive Manufacturing (CSAM) components; and

a mold having a recess;

wherein the system is configured to:

introducing (sucking) an unfinished workpiece;

cold spraying the additive material onto the unfinished workpiece with a CSAM assembly; and

superplastic forming with the SPFDB assembly on the unfinished workpiece with a die, thereby converting the unfinished workpiece to a finished workpiece having a shaped portion conforming to a shape defined by the recess.

A2. The system of a1, wherein the unfinished workpiece comprises a metal substrate having a metal selected from the list consisting of:

titanium, aluminum, and stainless steel.

A3. The system of a1, wherein the cold spraying of the additive material causes the finished workpiece to increase in thickness in the target area.

A4. The system of a3, wherein at least a portion of the target area overlaps at least a portion of the shaped portion.

A5. The system according to a3, wherein the increased thickness provides structural reinforcement of the finished workpiece in the target area.

A6. The system of a3, wherein the increased thickness of the finished workpiece in the target area tapers at the edges of the target area.

A7. The system according to a1, wherein the shaped portion is doubly curved.

A8. The system according to a1, wherein the cold spray uses helium or nitrogen.

A9. The system of a1, wherein removing the finished workpiece from the mold includes removing the finished workpiece from the mold using a release agent.

A10. A method of manufacturing a finished workpiece having a shaped portion, the method comprising:

cold spraying the additive material onto an unfinished workpiece;

positioning an unfinished workpiece on a mold having a recess;

superplastic forming the unfinished workpiece into a finished workpiece having a formed portion conforming to the shape defined by the recess; and

removing the finished workpiece from the mold, wherein the cold spraying of the additive material increases a thickness of the finished workpiece in the target area.

A11. The method according to a10, wherein the unfinished workpiece comprises a metal substrate having a metal selected from the list consisting of:

titanium, aluminum, and stainless steel.

A12. The method of a10, wherein at least a portion of the target area overlaps at least a portion of the shaped portion.

A13. The method of a10, wherein the increased thickness of the finished workpiece in the target area tapers at the edges of the target area.

A14. The method according to a10, wherein the shaped portion is doubly curved.

A15. The method according to a10, wherein the increased thickness provides structural reinforcement of the finished workpiece in the target area.

A16. The method according to a10, wherein the cold spraying uses helium or nitrogen.

A17. The method of a10, wherein removing the finished workpiece from the mold includes removing the finished workpiece from the mold using a release agent.

A18. A method of manufacturing a finished workpiece having a shaped portion, the method comprising:

cold spraying an additive material onto a mold having a recess;

positioning the unfinished workpiece on a mold;

superplastic forming an unfinished workpiece and diffusion bonding the cold sprayed additive material to the unfinished workpiece, thereby converting the unfinished workpiece to a finished workpiece having a formed portion conforming to a shape defined by the recess; and

removing the finished workpiece from the mold, wherein the cold spraying of the additive material increases a thickness of the finished workpiece in the target area.

A19. The method according to a18, wherein the unfinished workpiece comprises a metal substrate having a metal selected from the list consisting of:

titanium, aluminum, and stainless steel.

A20. The method of a18, wherein at least a portion of the additive material is cold sprayed into the recess, and wherein at least a portion of the target area overlaps at least a portion of the shaped portion.

A21. The method according to a18, wherein the increased thickness provides structural reinforcement of the finished workpiece in the target area.

A22. The method according to a18, wherein the cold spraying uses helium or nitrogen.

A23. The method of a18, wherein the increased thickness of the finished workpiece in the target area tapers at the edges of the target area.

A24. The method according to a18, wherein the shaped portion is doubly curved.

A25. The method of a18, wherein removing the finished workpiece from the mold includes removing the finished workpiece from the mold using a release agent.

A26. A method of manufacturing a finished workpiece having a shaped portion, the method comprising:

positioning an unfinished workpiece on a mold having a recess;

superplastically forming the unfinished workpiece to form a shaped portion on the unfinished workpiece, the shaped portion conforming to a shape defined by the recess;

removing the unfinished workpiece from the mold; and

cold spraying the additive material onto the unfinished workpiece, thereby converting the unfinished workpiece to a finished workpiece, wherein the cold spraying of the additive material increases a thickness of the finished workpiece in the target area.

A27. The method according to a26, wherein the unfinished workpiece comprises a metal substrate having a metal selected from the list consisting of:

titanium, aluminum, and stainless steel.

A28. The method of a26, wherein at least a portion of the target area overlaps at least a portion of the shaped portion.

A29. The method of a26, wherein the increased thickness of the finished workpiece in the target area tapers at the edges of the target area.

A30. The method according to a26, wherein the shaped portion is doubly curved.

A31. The method according to a26, wherein the increased thickness provides structural reinforcement of the finished workpiece in the target area.

A32. The method according to a26, wherein the cold spraying uses helium or nitrogen.

A33. The method of a26, wherein removing the unfinished workpiece from the mold includes removing the finished workpiece from the mold using a release agent.

A34. A method of manufacturing a finished workpiece having a shaped portion, the method comprising:

placing the cold sprayed additive material on a mold having a recess;

positioning the unfinished workpiece on a mold;

superplastic forming an unfinished workpiece and diffusion bonding the cold sprayed additive material to the unfinished workpiece, thereby converting the unfinished workpiece to a finished workpiece having a formed portion conforming to a shape defined by the recess; and

removing the finished workpiece from the mold, wherein the cold spraying of the additive material extends a length of the finished workpiece relative to a length of the unfinished workpiece.

A35. The method according to a34, wherein the unfinished workpiece comprises a metal substrate having a metal selected from the list consisting of:

titanium, aluminum, and stainless steel.

A36. The method of a34, wherein placing the cold sprayed additive material onto the mold includes cold spraying the additive material onto the mold.

A37. The method of a34, wherein placing the cold sprayed additive material onto the mold includes placing the cold sprayed additive material into the recess.

A38. The method of a34, wherein the cold sprayed additive material is tapered at its edges.

A39. The method according to a34, wherein the shaped portion is doubly curved.

A40. The method according to a34, wherein the cold spraying uses helium or nitrogen.

A41. The method of a34, wherein removing the finished workpiece from the mold includes removing the finished workpiece from the mold using a release agent.

A42. A method of manufacturing a finished workpiece having a shaped portion, the method comprising:

receiving a request for a finished part;

selecting a configuration for the CSAM component and the SPFDB component; configuring the CSAM component and the SPFDB component according to the selection;

receiving an unfinished workpiece; and

converting an unfinished workpiece to a finished workpiece, wherein converting comprises:

cold spraying the additive material onto the unfinished workpiece with a CSAM component; and

superplastic forming is performed on the unfinished workpiece with a die using an SPFDB assembly.

A43. A method of manufacturing a sandwich structure, the method comprising:

cold spraying an additive material onto at least one of a plurality of workpieces to be used in a sandwich structure;

superplastic forming and diffusion bonding a plurality of workpieces into a sandwich structure; and

cold spraying the additive material onto the sandwich structure.

A44. The method according to a43, wherein the sandwich structure comprises a 4-sheet sandwich structure.

A45. The method according to a43, wherein the increased thickness of the additive material provides structural reinforcement of the sandwich structure.

A46. The method according to a43, wherein the cold spraying uses helium or nitrogen.

When introducing elements of aspects of the present disclosure or the embodiments thereof, the articles "a," "an," "the," and "are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. The term "implementation" is intended to mean "an embodiment". The phrase "one or more of: A. b and C "mean" at least one of a and/or at least one of B and/or at least one of C ".

Having described aspects of the present disclosure in detail, it will be apparent that modifications and variations are possible without departing from the scope of aspects of the disclosure as defined in the appended claims. As various changes could be made in the above constructions, products, and methods without departing from the scope of aspects of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.