Cast component and methods of manufacturing with cold spraying

Abstract

A cast component includes a cast structure having a primary geometry formed by a mold. Also included is a structural deposit formed by cold spraying one or more layers of powdered material on an outer surface of the cast structure, the structural deposit defining at least one feature of the overall outer geometry of the cast component in addition to the primary geometry. Also provided are methods of manufacturing the cast component.

1 . A cast component comprising:
 a cast structure having a primary geometry formed by a mold; and   a structural deposit formed by cold spraying one or more layers of powdered material on an outer surface of the cast structure, the structural deposit defining at least one feature of the overall outer geometry of the cast component in addition to the primary geometry.   
     
     
         2 . The cast component of  claim 1 , wherein the cast component comprises at least one of an aluminum alloy, a titanium alloy, a steel alloy, and a magnesium alloy. 
     
     
         3 . The cast component of  claim 1 , wherein the cast component comprises a component for an aircraft. 
     
     
         4 . The cast component of  claim 1 , wherein the cast structure is a sand cast structure. 
     
     
         5 . A method of manufacturing a component comprising:
 casting a structure having a primary geometry with a mold; and   depositing a structural deposit by cold spraying one or more layers of powdered material on an outer surface of the cast structure with a cold spray nozzle to define at least one feature of the overall outer geometry of the component in addition to the primary geometry.   
     
     
         6 . The method of  claim 5 , further comprising post-processing at least one of the primary geometry and the at least one feature of the structure. 
     
     
         7 . The method of  claim 5 , wherein casting the structure comprises casting with a sand casting mold. 
     
     
         8 . The method of  claim 5 , wherein depositing the structural deposit comprises moving the structure. 
     
     
         9 . The method of  claim 5 , wherein depositing the structural deposit comprises moving the cold spray nozzle. 
     
     
         10 . The method of  claim 5 , wherein depositing the structural deposit comprises coupling the cold spray nozzle to a numerically controlled machine, wherein a deposition path is automated. 
     
     
         11 . The method of  claim 5 , wherein depositing the structural deposit comprises coupling the structure to a numerically controlled machine, wherein a deposition path is automated. 
     
     
         12 . The method of  claim 5 , wherein the powdered material comprises at least one of an aluminum alloy, a titanium alloy, a steel alloy, and a magnesium alloy. 
     
     
         13 . The method of  claim 5 , wherein cold spraying comprises accelerating powder particles with a gas comprising at least one of helium and nitrogen. 
     
     
         14 . The method of  claim 5 , wherein the component comprises a component for an aircraft. 
     
     
         15 . A method of manufacturing a component comprising:
 forming a mold for casting a structure, the mold having a primary geometry;   depositing a structural deposit by cold spraying one or more layers of powdered material on a surface of the mold to define at least one feature of the overall geometry of the structure in addition to the primary geometry; and   casting the structure within the mold.