Method of Electroforming a Component

This application claims priority to Indian Provisional Application No. 20/241,1030197, filed Apr. 15, 2024, the disclosure of which is hereby incorporated by reference in its entirety as though fully set forth herein.

The disclosure generally relates to a method of forming a component and, more specifically, a method of forming a high-strength component.

Turbine engines, and particularly gas or combustion turbine engines, are rotary engines that extract energy from a flow of combusted gases passing through the engine in a series of compressor stages, which include pairs of rotating blades and stationary vanes, through a combustor, and then onto a multitude of turbine stages, also including multiple pairs of rotating blades and stationary vanes.

Higher operating temperatures for gas turbine engines are continuously being sought to improve their efficiency. However, as operating temperatures increase, the high temperature durability of the components of the engine must correspondingly increase. Significant advances in high temperature capabilities have been achieved through the formulation of superalloys. While superalloys have found wide use for components used throughout gas turbine engines, and especially in the higher temperature sections, alternative options are desired for both weight, cost, and processing reasons (for example, the hardness of superalloys makes them difficult to machine).

Aspects of present disclosure relate to a high-strength component. More specifically, aspects of the disclosure relate to high-strength alloy components formed via a multi-step method including, electroforming and a secondary process such as x-iding. As used herein, “x-iding” is a deposition process that results in a surface layer of a particular element or alloy. By way of non-limiting example, x-iding where the resulting surface layer includes aluminum could be considered aluminiding.

While it should be understood that the component can be any suitable component, much of the disclosure will focus on a duct assembly or conduit for providing a flow of fluid from one portion of a gas turbine engine to another portion of the gas turbine engine. Gas turbine engines have been used for land and nautical locomotion and power generation, but are most commonly used for aeronautical applications such as for airplanes, including helicopters. In airplanes, gas turbine engines are used for propulsion of the aircraft. It will be understood, however, that the disclosure is not so limited and can have general applicability in non-aircraft applications, such as other mobile applications and non-mobile industrial, commercial, and residential applications. Further still, such methods can be utilized to make any suitable high-strength components.

An electroforming process can create, generate, or otherwise form a metallic layer on a component or mandrel. In one example of the electroforming process, a mold or base for the desired component can be submerged in an electrolytic liquid and electrically charged. The electric charge of the mold or base can attract an oppositely-charged electroforming material through the electrolytic solution or electrolytic fluid. The attraction of the electroforming material to the mold or base ultimately deposits the electroforming material on the exposed surfaces of the mold or base, creating an external metallic layer and forming a net shape part. Electroformed alloys are currently limited to solid-solution strengthened alloys. Solid solution strengthening is a type of alloying that can be used to improve the strength of a pure metal. The technique works by adding atoms of one element to the crystalline lattice of another element, forming a solid solution. Conventional electroforming processes can only produce a simple alloy containing two or three elements, wherein the choice of elements is restricted. Further, conventional electroforming cannot produce a superalloy which contains multiple elements or include active elements like Al or Ti.

Therefore, aspects of the disclosure present a process to add additional performance features to the electroformed part. This can include, among other things, higher-strength at high temperatures than would not be achievable with the electroformed part without the post processing. By way of a non-limiting example, the electroformed part can be precipitation strengthened by the gamma-prime forming elements such as Al, Si, Ta, Ti, etc. The disclosure provides a method for introducing these elements via a secondary process post electroforming as they currently cannot be incorporated in the electroforming process.

As used herein “a set” can include any number of the respectively described elements, including only one element. Additionally, all directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the present disclosure. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order, and relative sizes reflected in the drawings attached hereto can vary.

In the present disclosure, when a layer is being described as “on” or “over” another layer or substrate, it is to be understood that the layers can either be directly contacting each other or have another layer or feature between the layers, unless expressly stated to the contrary. Thus, these terms are simply describing the relative position of the layers to each other and do not necessarily mean “on top of” since the relative position above or below depends upon the orientation of the device to the viewer.

The exemplary drawings are for purposes of illustration only and the dimensions, positions, order, and relative sizes reflected in the drawings attached hereto can vary.

is a schematic cross-sectional diagram of a gas turbine enginefor an aircraft. The enginehas a generally longitudinally extending axis or centerlineextending from forwardto aft. The engineincludes, in downstream serial flow relationship, a fan sectionincluding a fan, a compressor sectionincluding a booster or low pressure (LP) compressorand a high pressure (HP) compressor, a combustion sectionincluding a combustor, a turbine sectionincluding a HP turbine, and a LP turbine, and an exhaust section.

The fan sectionincludes a fan casingsurrounding the fan. The fanincludes a set of fan bladesdisposed radially about the centerline. The HP compressor, the combustor, and the HP turbineform a coreof the engine, which generates combustion gases. The coreis surrounded by core casing, which can be coupled with the fan casing.

An HP shaft or spooldisposed coaxially about the centerlineof the enginedrivingly connects the HP turbineto the HP compressor. A LP shaft or spool, which is disposed coaxially about the centerlineof the enginewithin the larger diameter annular HP spool, drivingly connects the LP turbineto the LP compressorand fan. The portions of the enginemounted to and rotating with either or both of the spools,are also referred to individually or collectively as a rotor.

The LP compressorand the HP compressorrespectively include a set of compressor stages,, in which a set of compressor blades,rotate relative to a corresponding set of static compressor vanes,(also called a nozzle) to compress or pressurize the stream of fluid passing through the stage. In a single compressor stage,, multiple compressor blades,can be provided in a ring and can extend radially outwardly relative to the centerline, from a blade platform to a blade tip, while the corresponding static compressor vanes,are positioned downstream of and adjacent to the rotating blades,. It is noted that the number of blades, vanes, and compressor stages shown inwere selected for illustrative purposes only, and that other numbers are possible. The blades,for a stage of the compressor can be mounted to a disk, which is mounted to the corresponding one of the HP and LP spools,, respectively, with stages having their own disks. The vanes,are mounted to the core casingin a circumferential arrangement about the rotor.

The HP turbineand the LP turbinerespectively include a set of turbine stages,, in which a set of turbine blades,are rotated relative to a corresponding set of static turbine vanes,(also called a nozzle) to extract energy from the stream of fluid passing through the stage. In a single turbine stage,, multiple turbine blades,can be provided in a ring and can extend radially outwardly relative to the centerline, from a blade platform to a blade tip, while the corresponding static turbine vanes,are positioned upstream of and adjacent to the rotating blades,. It is noted that the number of blades, vanes, and turbine stages shown inwere selected for illustrative purposes only, and that other numbers are possible.

In operation, the rotating fansupplies ambient air to the LP compressor, which then supplies pressurized ambient air to the HP compressor, which further pressurizes the ambient air. The pressurized air from the HP compressoris mixed with fuel in the combustorand ignited, thereby generating combustion gases. Some work is extracted from these gases by the HP turbine, which drives the HP compressor. The combustion gases are discharged into the LP turbine, which extracts additional work to drive the LP compressor, and the exhaust gas is ultimately discharged from the enginevia the exhaust section. The driving of the LP turbinedrives the LP spoolto rotate the fanand the LP compressor.

Some of the air from the compressor sectioncan be bled off via one or more duct assemblies(shown schematically), and be used for cooling of portions, especially hot portions, such as the HP turbine, or used to generate power or run environmental systems of the aircraft such as the cabin cooling/heating system or the deicing system. In the context of a gas turbine engine, the hot portions of the engine are normally downstream of the combustor, especially the turbine section, with the HP turbinebeing the hottest portion as it is directly downstream of the combustion section. Air that is drawn off the compressor and used for these purposes is known as bleed air.

Additionally, the ducts, or metal tubular elements thereof, can also be a fluid delivery system for routing a fluid through the engine, including through the duct assemblies. The duct assemblies, such as air duct or other ducting assemblies leading either internally to other portions of the gas turbine engineor externally of the gas turbine engine, can also include one or more metal tubular elements or metallic tubular elements forming ducts or conduits configured to convey fluid from a first portion of the engineto another portion of the engine. In addition, duct assembliesleading internally to portions of the gas turbineare exposed to high temperatures during operation. Components formed by the process disclosed herein that includes electroforming, x-iding, and a heat treatment can provide a component having advantages such as greater strength properties, increased high-temperature resistance, reduced corrosion, oxidation resistance, or a combination thereof.

An example electroforming process is illustrated by way of an electrodeposition bathin. As used herein, “electroforming” or “electrodeposition” can include any process for building, forming, growing, or otherwise creating a metal layer over another substrate or base. Non-limiting examples of electrodeposition can include electroforming, electroless forming, electroplating, or a combination thereof. While the remainder of the disclosure is directed to electroforming, any and all electrodeposition processes are equally applicable. An exemplary bath tankcarries a solution. The solutioncan include an aqueous electrolyte containing dissolved salts. The solution, in one non-limiting example, can include a single metal ion constituent solution. By way of a further non-limiting example this can include a solution from which a nickel alloy can be deposited. In another non-limiting example, a nickel-cobalt alloy can be deposited from an electrolyte solution containing both nickel and cobalt ions.

As shown in, an anodespaced from a cathodeis provided in the bath tankand submerged in the solution. The anodecan be sacrificial or consumable anode or an inert anode. While one anode is shown, it should be understood that the bath tankcan include any number of anodesas desired. A substrate, base, or component is illustrated, by way of non-limiting example, as a sacrificial mandrel. The sacrificial mandrelis utilized in forming at least a portion of a component. In the illustrated example, the componentis shown as a duct, suitable for use in by way of non-limiting example, the duct assembly. The sacrificial mandrelitself can be formed via additive manufacturing, injection molding, or any other suitable process. The sacrificial mandrelcan include, by way of non-limiting examples, materials such as plastics/polymers, wax, or aluminum, and in any desired configuration such as solid, hollow, or foam. The componentcan be, by way of non-limiting example, any component in or coupled to the gas turbine engine. In other words, the componentcan be in the compressor section, the combustion section, the turbine section, or external of the gas turbine engine, such as, but not limited to, tubes or ducts. While illustrated as the duct, the componentcan be a blade or vane or components that hang or otherwise couple to the blade or vane from one or more of the set of compressor blades,, the set of static compressor vanes,, the multiple turbine blades,, or the static turbine vanes,. The ductcan form the cathode, having electrically conductive material. It is also contemplated that a conductive spray or similar treatment can be provided to the sacrificial mandrelto facilitate formation of the cathode. In addition, while illustrated as one cathode, it should be appreciated that one or more cathodes are contemplated for use in the bath tank.

A controller, which can include a power supply, can electrically couple to the anodeand the cathodeby electrical conduitsto form a circuit via the conductive metal constituent solution. Optionally, a switchor sub-controller can be included along the electrical conduits, between the controllerand the anodeand the cathode.

During operation, a current can be supplied from the anodeto the cathodeto electroform or electrodeposit a monolithic body on the sacrificial mandrel. More specifically metal ions from the solutioncan be deposited as metal on the sacrificial mandrelto form a metallic layer. During supply of the current, nickel, iron, or nickel and cobalt from the solutionform the metallic layersuch as, but not limited to, iron (Fe) metallic layer, cobalt (Co) metallic layer, nickel (Ni) metallic layer, nickel-cobalt (NiCo) metallic layer, or nickel-cobalt-phosphorous metallic layer over the sacrificial mandrelto form the duct. That is, the metallic layerby way of non-limiting example, can be one or more of elemental Fe, Co, Ni, NiCo, NiCoP, or alloys thereof. The sacrificial mandrelcan then be removed, recycled, or “sacrificed,” from the duct, including by way of melting, such as through application of heat to the sacrificial mandrel, or by dissolving, e.g. a chemical dissolving process, in non-limiting examples.

is a schematic cross-sectional view of a portion of the ductremoved from the sacrificial mandrel. The metallic layerforms a duct wall. More specifically, the duct wallis an annular duct wall having an exterior surfaceand an interior surfacebounding an internal passage. The duct wallincludes a metallic layer thickness. It will be understood that the metallic layer thicknessis bounded by the exterior surfaceand the interior surface. In a non-limiting example, the metallic layer thicknesscan be in a range from 25 micrometers (μm) to 5000 micrometers (μm). This range can provide structural rigidity while adding a minimal weight to the part. In a non-limiting example, the metallic layer thickness can be in a range of 250 micrometers (μm) to 5000 micrometers (μm) for applications to create thicker componentswith the surface strengthened. In another example, the metallic layer thicknesscan be in a range from 25 micrometers (μm) to 250 micrometers (μm) to create componentsstrengthened across the entire metallic layer thickness. That is, componentswith the metallic layer thicknessthat is in a range from 25 micrometers (μm) to 250 micrometers (μm) provide the required structural stiffness while minimizing cost of material and weight. It is contemplated in another non-limiting example, that the metallic layer thicknesscan have a variable metallic layer thickness through portions of the duct. The term “variable thickness” used herein, is defined as non-constant or a not consistent thickness along the direction of the length L of the duct. It is further contemplated, that the ductcan be at least one of non-linear or non-circular. Once the ductis removed from the electrodeposition bath, the ductcan be moved to a layer forming systemand then a heat-treating device, described further inand. Optionally, the ductis removed from the sacrificial mandrelprior to being moved to the layer forming systemor the heat-treating device.

illustrates the ductafter a surface layerhas been deposited on the exterior surfaceof the duct wallby the layer forming system(). It is contemplated that the composition of the surface layercan include at least one alloying element. The at least one alloying element is selected from a group of: aluminum (Al), silicon (Si), tantalum (Ta), titanium (Ti), chromium (Cr), and boron (B). It is contemplated in a non-limiting example, that the surface layercan include multiple alloying elements including, by way of further non-limiting example that the multiple alloying elements are selected from the group of: Al, Si, Ta, Ti, Cr, and B. It is contemplated that the surface layercan be formed on the interior surfaceof the duct wallas well as the exterior surface; however, the remainder of the application illustrates the surface layeronly on the exterior surfaceof the duct wall.

In a non-limiting example, the layer deposition system() can include any x-iding system. That is, the surface layercan be deposited by x-iding wherein the “x” in x-iding can include at least one of Al, Si, Ta, Ti, Cr, or B. The x-iding deposition process can include any suitable deposition process including vapor phase deposition or pack cementation by way of non-limiting examples. The surface layerdeposited via the x-iding process has a surface layer thickness. In a non-limiting example, the surface layerhas a thickness in a range of 12.5 micrometers (μm) to 130 micrometers (μm). That is, the surface layercan fully infiltrate the metallic layerwithout leaving a residual layer of the surface layerwhen the surface layer thickness is in range a of 12.5 micrometers (μm) to 130 micrometers (μm).

The metallic layercan be welded prior to forming a surface layer. That is, the metallic layerof the ductcan be machined to include interior holes and channels of small dimensions or be joined with another part prior to the forming of the surface layer, which includes elements that are less conducive to welding. Once the ductis deposited with the surface layer, the ductcan be moved to the heat-treatment device(), described further in.

is a schematic cross-sectional view of the duct wallafter completion of a first heat-treatment in the heat-treatment device(). In a non-limiting example, the heat-treatment device() can include an oven or a furnace. It will be understood that the ductcan go through at least one heat treatment following formation of the surface layer(). The at least one heat treatment can include stress equalizing, stress relieving, annealing, solution annealing, tempering, age hardening, precipitation hardening, or diffusion, in some non-limiting examples. It is contemplated that the at least one heat treatment can include a first heat treatment performed at a first temperature. The remainder of the disclosure will discuss a two-step heat treating process, but it will be understood that any suitable heat treating can be utilized.

In a non-limiting example, the ductincluding the surface layer() is heated at a treatment temperature in a range of 500° C. to 1200° C. during the first heat-treatment. That is, the treatment temperature in a range of 500° C. to 1200° C. is the range in which Gamma-prime precipitate phase is formed. The first heat-treatment forms a distribution of particlesof the at least one alloying element throughout the metallic layer thickness() of the duct wall. That is, the at least one alloying element infiltrates the duct wall. The duct wallhas a relatively high concentration of particlesof the at least one alloying element near the exterior surface() and a relatively low concentration of particlesof at least one alloying element near the interior surface. In a non-limiting example, the first heat-treatment is further configured to homogenize the distribution of the particlesof the at least one alloying element within the duct wall. It is understood that, in some examples, the particlescan have a uniform or non-uniform arrangement, distribution, or the like after performing the first heat treatment.

In another non-limiting example, the first heat treatment creates a distribution of formed gamma-prime particles. Gamma-prime particles are an intermetallic phase that precipitate out of the alloy matrix in a second heat treatment which is described further in. Gamma-prime precipitate phase can include nickel-aluminide (NiAl) or nickel-titanium (NiTi) by way of non-limiting examples.

is a schematic cross-sectional view of a portion the duct wallafter completion of a second heat-treatment following the first heat-treatment illustrated in. It is understood that the second heat-treatment can form precipitateswithin the duct wall. The formation of these precipitates leads to precipitate strengthening which enables the material to have high strength at high temperatures. Precipitation strengthening relies on changes in solid solubility and temperature to produce fine particles of an intermetallic phase. The fine particles of the intermetallic phase impede the movement of dislocations, or defects in a crystal lattice. The impeded movement of dislocations serves to harden a material. Precipitation in solids can produce many different sizes of particles, which have different properties. In order to allow complete precipitation to take place, alloys must be kept at a predetermined elevated temperature for sufficient time. This heat-treatment step is typically referred to as an aging heat-treatment.

In the illustrated example, formation of the precipitatescan be limited to locations of the particlesand not within the entire duct wall. However, the precipitatescan form homogeneously across the entire duct wall. It is further contemplated that, in some examples, the second heat-treatment can be performed once, forming a single-step aging process, or performed multiple times to form a multi-step aging process.

graphically illustrates an exemplary heat-treating schedule that can be performed on a component such as the duct, by the heat-treating device(). In the non-limiting example illustrated, the first heat-treatment starts atwhere the temperature of the component is at ambient temperature. The temperature of the component gradually increases to a range of 500° C. to 1200° C., at. This temperature can be held for a duration such as by way of non-limiting example, of 24 hours. At, the temperature of the component can be equal to the temperature of the component ator can be within a range of 10% to 15% of the temperature of the component at. The temperature of the component is decreased to ambient temperature. In a non-limiting example, the temperature of the component can be decreased by one or more of water quenching, air cooling, or furnace cooling.

At, the second heat-treatment is performed. It is contemplated in a non-limiting example, that the start of the second heat-treatment can be performed immediately after the first heat-treatment. However, it is contemplated in another non-limiting example, that the second heat-treatment can be performed a predetermined amount of time after the first heat-treatment. In the exemplary graphical illustration shown, the second heat-treatment is a single-step aging process. The temperature of the component is increased to a range of 500° C. to 1200° C. at. In a non-limiting example, the temperature of the component atcan be less than the temperature of the component atandof the first heat treatment. Further, the second heat-treatment is performed for a predetermined duration, such as for example, 8 hours. The component is held at the elevated temperature fromto. At, the temperature of the component can be equal to the temperature of the component ator can be within a range of 10% to 15% of the temperature of the component at. The temperature of the component is then decreased to ambient temperature at. In a non-limiting example, the temperature of the component can be decreased by one or more of water quenching, air cooling, or furnace cooling.

graphically illustrates another exemplary heat-treating schedule that can be performed on a component, such as the duct. In the non-limiting example illustrated, the first heat-treatment starts atwhere the temperature of the component is at ambient temperature. The temperature of the component gradually increases to a range of 500° C. to 1200° C. at. This temperature can be held for a duration such as by way of non-limiting example, of 24 hours. At, the temperature of the component can be equal to the temperature of the component ator can be within a range of 10% to 15% of the temperature of the component at. At, the temperature of the component is decreased to ambient temperature. In a non-limiting example, the temperature of the component can be decreased by one or more of water quenching, air cooling, or furnace cooling.

At, the second heat-treatment is performed. It is contemplated in a non-limiting example, that the start of the second heat-treatment can be performed immediately after the first heat-treatment. However, it is contemplated in another non-limiting example, that the second heat-treatment can be performed a predetermined amount of time after the first heat-treatment. In the exemplary graphical illustration shown, the second heat-treatment is a multi-step aging process. At, the temperature of the component is increased to a range of 500° C. to 1200° C. In a non-limiting example, the temperature of the component atcan be less than the temperature of the component atandof the first heat treatment. Further, a first step of the multi-step aging a process is performed for a predetermined duration, such as for example, 4 hours. The component is held at the elevated temperature fromto. At, the temperature of the component can be equal to the temperature of the component ator can be within a range of 10% to 15% of the temperature of the component at. At, the temperature of the component is decreased. For example, the temperature can be decreased by 25% to 50% of the temperature of the component at. In the non-limiting example shown, the rate of decrease of the temperature of the component betweenandhas a linear decay. However, it is contemplated in another non-limiting example, that the rate of decrease of the temperature of the component betweenandcan have an exponential decay, as illustrated at.

At, a second step of the multi-step aging process is performed for a predetermined duration, such as for example, 4 hours. In another non-limiting example, the temperature of the component can be decreased by one or more of water quenching, air cooling, or furnace cooling. At, the temperature of the component can be equal to the temperature of the component ator within a range of 10% to 15% of the temperature of the component at. At, the temperature of the component is decreased to ambient temperature.

illustrates a methodof forming the componentsuch as the duct. At, a body, such as the duct wall(), can be formed by way of electrodeposition of the metallic layer() over an exposed surface of the sacrificial mandrel(). At, the sacrificial mandrel() can be removed including by melting or dissolving. At, the surface layer() including at least one alloying element is formed on the duct wall(), where the at least one alloying element can include Al, Si, Ta, Ti, Cr, or B. Atthe duct wall() with the surface layer() is heat treated by the first heat-treatment, where the first heat-treatment is configured to infiltrate the at least one alloying element into the duct wall(). Optionally, atthe componentis heat treated in the second heat-treatment, where the second heat-treatment is configured to form precipitates in the duct wall(). In a non-limiting example, during the formation of precipitates, appropriate thermodynamic and diffusion kinetics models can be used to determine the amount of gamma-prime precipitate phase, thereby obtaining the desired strength and balance of properties.

A specific example may prove useful but should not be seen as limiting on the disclosure. In such an example a 250 micrometers (μm) thick Ni matrix can be formed via electroforming. For such a thickness it has been determined that approximately 69 micrometers (μm) of an Al surface layer is desirable for infiltration of the entire surface layer() and homogenous distribution of precipitates() across the metallic layer thickness(). For example, such surface layer can be deposited onto the Ni metallic layer via vapor phase aluminiding. For example, a hydrogen halide gas, such as hydrogen chloride or hydrogen fluoride, is contacted with aluminum metal or an aluminum alloy to form the corresponding aluminum halide gas.

In a non-limiting example, if the metallic layer() is elemental Ni and the at least one alloying element in the surface layer() is Al, the first heat-treatment infiltrates the Al into the metallic layerand the second heat-treatment creates a strengthened precipitate of nickel-aluminide (NiAl). The volume of gamma-prime precipitate phase of NiAl in the metallic layerdictates the strength of the component. If all of the Al is uniformly infiltrated, in a non-limiting example, into the Ni-matrix via a heat-treatment step, and then the appropriate aging heat-treatment is carried out approximately 50 mol. % of NiAl (strengthening precipitate) is achieved. It will be understood that this is only a simple illustrative example, and a similar strategy can used to infiltrate other active alloying elements for achieving the right chemistry, microstructure, and therefore balance of properties. Other elements may be doped into the surface layer from a corresponding gas, if desired. The deposition technique allows alloying elements to be co-deposited into the surface layer if desired, from the halide gas. It will be further understood that one or more alloying elements can be created as a surface layer depending on the balance of properties required in the final component or multiple surface layers with appropriate heat treatment steps can be utilized to obtain the desired balance of properties for the component.

is a flowchart diagram illustrating a methodof repairing the componentsuch as the ductaccording to various aspects of the disclosure. The methodcan be utilized to repair a component having performed at least one cycle of operation. The component can include, for example, foreign object damage or other physical aspects that require the component to be repaired. At, the surface layer() of ductcan be removed, including chemical stripping such as submerging the componentin a chemical bath of inorganic acids, sand or water jet blasting, or any combination thereof. At, the ductstripped to the metallic layer() can be welded or brazed to repair portions of the duct wall(). At, the surface layer() including at least one alloying element is formed on the duct wall(), where the at least one alloying element can include Al, Si, Ta, Ti, Cr, or B. At, the duct wall() with the surface layer() is heat treated by the first heat-treatment, where the first heat-treatment is configured to infiltrate the at least one alloying element. At, the componentis heat treated in the second heat-treatment, where the second heat-treatment is configured to form precipitates. In a non-limiting example, the surface layeris strengthened by infiltration and precipitation formation, and the metallic layer is left as nickel, cobalt, iron, nickel-cobalt, or nickel-cobalt-phosphorous alloy in the core or central region. Referring generally to, it is contemplated that a second surface layer can be formed on the metallic layerof the component. The second surface layer can be of at least one other alloying element, where the at least one other alloying element can be Al, Si, Ta, Ti, Cr, or B. The addition of a second surface layer can be followed by second heat treating of the component. More than one surface layer followed by a heat treating can create the desired balance of the properties for the component. In addition, the method ofcan be repeated to form a componentwith a greater thickness. That is, the repetition of the method ofcreates a thicker componentwith a uniform distribution of the strengthening precipitates.

It is further contemplated that the methods described herein, can be utilized to form functionally gradient materials. The term “functionally gradient materials”, used herein can be defined as multifunctional materials, which contain a variation in one or both of composition and microstructure for the specific purpose of controlling variations in thermal, structural, or functional properties. That is, in a non-limiting example, the specific geometry or elemental make-up of one or more surface layersdeposited on the metallic layer, allows the componentto have areas of differing functional properties. In another non-limiting example, differing functional properties can include the exterior surfacebeing harder than the interior surface.

Aspects of the present disclosure provide for a variety of benefits. In one aspect, a process including the deposition of gamma-prime forming elements such as aluminum, silicon, tantalum, or titanium within an electroformed part allows for components with additional properties from those formed merely through electroforming. For example, inclusion of aluminum or titanium can provide greater strength properties. Inclusion of elements such as chromium, boron, or silicon can provide improved corrosion and oxidation resistance. Multiple surface layers of different alloying elements can provide for thicker walled parts with high strength from the gamma-prime forming elements and corrosion and oxidation resistance from the elements such as boron or silicon.

To the extent not already described, the different features and structures of the various embodiments may be used in combination with each other as desired. That one feature may not be illustrated in all of the embodiments and is not meant to be construed that it may not be but is done for brevity of description. Thus, the various features of the different embodiments may be mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described. All combinations or permutations of features described herein are covered by this disclosure.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Further aspects are provided by the subject matter of the following clauses:

A method comprising forming a component by way of electrodeposition of a metallic layer over an exposed surface of a sacrificial mandrel, removing the sacrificial mandrel, forming a surface layer of at least one alloying element on the metallic layer, heat treating the component having the metallic layer and the surface layer of at least one alloying element.

The method of any preceding clause, wherein the metallic layer is one of elemental nickel, cobalt, iron, or nickel-cobalt alloy.

The method of any preceding clause, wherein the at least one alloying element is selected from a group of: aluminum, silicon, tantalum, titanium, chromium, and boron.

The method of any preceding clause, wherein the metallic layer has a thickness of 25 micrometers to 5000 micrometers.