High strength vibrational-dampened components

Abstract

An article that includes a polymer-based substrate; and a metallic nano-crystalline coating on at least a portion of the polymer-based substrate, where the metallic nano-crystalline coating defines an average grain size less than about 20 nanometers, where the portion of the polymer-based substrate has a first Young's modulus and the metallic nano-crystalline coating has a second Young's modulus, where the first Young's modulus is at least five times less than the second Young's modulus.

What is claimed is: 
     
         1 . An article comprising:
 a polymer-based substrate; and   a metallic nano-crystalline coating on at least a portion of the polymer-based substrate, wherein the metallic nano-crystalline coating defines an average grain size less than about 20 nanometers,   wherein the portion of the polymer-based substrate has a first Young's modulus and the metallic nano-crystalline coating has a second Young's modulus, wherein the first Young's modulus is at least five times less than the second Young's modulus.   
     
     
         2 . The article of  claim 1 , wherein the polymer-based substrate comprises a plurality of reinforcement fibers embedded in a polymeric material. 
     
     
         3 . The article of  claim 2 , wherein the plurality of reinforcement fibers are non-uniformly distributed in the polymer-based substrate. 
     
     
         4 . The article of  claim 1 , further comprising a dense core material, wherein the polymer-based substrate substantially surrounds the dense core material. 
     
     
         5 . The article of  claim 1 , wherein the polymer-based substrate includes a polymeric material selected from the group consisting of polyether ether ketone (PEEK), polyamide (PA), polyimide (PI), bis-maleimide (BMI), epoxy, phenolic polymers (e.g., polystyrene), polyesters, polyurethanes, silicone rubbers, and combinations thereof. 
     
     
         6 . The article of  claim 1 , wherein the metallic nano-crystalline coating comprises:
 a first layer comprising nano-crystalline cobalt defining a first thickness; and   a second layer comprising nano-crystalline nickel defining a second thickness, wherein the first thickness is greater than the second thickness.   
     
     
         7 . The article of  claim 1 , wherein the article comprises an aerospace component comprising at least one of a rotor, a disc, a turbine blade, a housing element, a bracket, a chevron ventilation outlet, a vane box plume tab, a variable vane actuator arm, a nose cone, an airfoil, a flap, an accessory gear, or an air-flow surface. 
     
     
         8 . The article of  claim 1 , further comprising a metal-polymer laminate on the polymer-based substrate, wherein the metal-polymer laminate comprises:
 a first metallic nano-crystalline layer comprising the metallic nano-crystalline coating;   at least one polymer-based layer on the first metallic nano-crystalline coating; and   a second metallic nano-crystalline layer on the least one polymer-based layer, wherein the second metallic nano-crystalline layer defines an average grain size less than about 20 nanometers.   
     
     
         9 . The article of  claim 1 , wherein the polymer-based substrate comprises a truss structure defining a plurality of truss supports. 
     
     
         10 . An article comprising:
 a polymer-based substrate; and   a metallic nano-crystalline coating on at least a portion of the polymer-based substrate, wherein the metallic nano-crystalline coating defines an average grain size less than about 20 nanometers,   wherein the portion of the polymer-based substrate has a first Young's modulus and the metallic nano-crystalline coating has a second Young's modulus, and wherein the first and second Young's modulus are selected to dampen a predetermined vibration frequency in the article.   
     
     
         11 . The article of  claim 10 , wherein the polymer-based substrate comprises a polymeric material and a plurality of reinforcement fibers embedded in the polymeric material. 
     
     
         12 . The article of  claim 10 , further comprising a dense core material, wherein the polymer-based substrate substantially surrounds the dense core material, and wherein the dense core material comprises a metal or a metal alloy having a density between about 2.5 grams per cubic centimeter (g/cm 3 ) and about 9.0 g/cm 3 . 
     
     
         13 . The article of  claim 10 , wherein the metallic nano-crystalline coating comprises:
 a first metallic nano-crystalline layer defining a first thickness; and   a second metallic nano-crystalline layer defining a second thickness, wherein the first thickness is different than the second thickness.   
     
     
         14 . The article of  claim 11 , wherein the metallic nano-crystalline coating comprises an overall thickness measured normal to an exterior surface of the polymer-based substrate, wherein the overall thickness is selectively varied on different regions of the polymer-based substrate. 
     
     
         15 . The article of  claim 11 , further comprising a metal-polymer laminate on the polymer-based substrate, wherein metal-polymer laminate comprises:
 a first metallic nano-crystalline layer comprising the metallic nano-crystalline coating;   at least one polymer-based layer on the first metallic nano-crystalline coating; and   a second metallic nano-crystalline layer on the least one polymer-based layer, wherein the second metallic nano-crystalline layer defines an average grain size less than about 20 nanometers.   
     
     
         16 . A method for forming an aerospace component comprising:
 forming a polymer-based substrate comprising a polymeric material; and   depositing a metallic nano-crystalline coating on at least a portion of the polymer-based substrate, wherein the metallic nano-crystalline coating defines an average grain size less than about 20 nanometers, wherein the portion of the polymer-based substrate has a first Young's modulus and the metallic nano-crystalline coating has a second Young's modulus, wherein the first and second Young's modulus are selected to dampen a vibration in the article at a predetermined frequency.   
     
     
         17 . The method of  claim 16 , wherein forming a polymer-based substrate comprises embedding a plurality of reinforcement fibers in the polymeric material, wherein the plurality of reinforcement fibers are non-uniformly distributed in the polymer-based substrate. 
     
     
         18 . The method of  claim 16 , further comprising forming a dense core material comprising a metal or a metal alloy having a density of about 2.5 grams per cubic centimeter (g/cm 3 ) and about 9.0 g/cm 3 , wherein the polymer-based substrate at least partially encases the dense core material. 
     
     
         19 . The method of  claim 16 , further comprising:
 depositing at least one polymer-based layer on the metallic nano-crystalline coating; and   depositing at least one additional metallic nano-crystalline layer on the at least one polymer-based layer.   
     
     
         20 . The method of  claim 16 , further comprising selectively varying a thickness of the metallic nano-crystalline coating as measured normal to an exterior surface of the polymer-based substrate.