Electroforming method and system

Abstract

An electroforming system and method includes disposing an electrode defining a mandrel within a mixture solution, and applying a voltage to the electrode in the mixture solution to form a composite metal layer on the electrode. The composite metal layer can have particles incorporated within a metal matrix and define a composite electroformed component.

What is claimed is: 
     
         1 . A method of forming a component, the method comprising:
 electroforming a composite metal layer onto a mandrel from a mixture solution, the mixture solution comprising an electrolytic solution with dispersed metallic powder particles therein having an average particle size between 0.1-1000 micrometers, and with the composite metal layer having the metallic powder particles incorporated within a metal matrix and defining a composite electroformed component; and   performing at least a first heat treatment on the composite electroformed component within a first temperature range of 600-1200° C.   
     
     
         2 . The method of  claim 1 , wherein the metallic powder particles comprise at least one of a superalloy, a high strength alloy, nickel, aluminum, titanium, tantalum, niobium, cobalt, phosphorus, molybdenum, or steel. 
     
     
         3 . The method of  claim 1 , further comprising performing an aging heat treatment on the composite electroformed component, subsequent to the first heat treatment, within a second temperature range of 500-800° C. to form precipitates in the composite electroformed component. 
     
     
         4 . The method of  claim 3 , wherein the aging heat treatment forms the precipitates within the metallic powder particles. 
     
     
         5 . The method of  claim 3 , wherein the first heat treatment dissolves the metallic powder particles into the metal matrix to define a second matrix, and wherein the precipitates are formed within the second matrix. 
     
     
         6 . The method of  claim 3 , wherein the precipitates comprise at least one of Ni 3 Al, Ni 3 Ta, Ni 3 Ti, Ni 3 Nb, Ni 3 Mo, NiAl, or Ni 3 Ti. 
     
     
         7 . The method of  claim 1 , wherein the metallic powder particles in the mixture solution have a coating comprising at least one of ceramic or a native oxide of the metallic powder particles. 
     
     
         8 . The method of  claim 7 , further comprising growing the native oxide onto the metallic powder particles to form the coating. 
     
     
         9 . The method of  claim 7 , wherein the first heat treatment removes the coating from the metallic powder particles and incorporates the coating into the metal matrix. 
     
     
         10 . The method of  claim 1 , further comprising dispersing the metallic powder particles within the mixture solution by at least one of: applying pressure waves to the mixture solution, flowing a liquid jet through the mixture solution, or flowing an air jet through the mixture solution. 
     
     
         11 . The method of  claim 10 , wherein the mandrel includes a non-horizontal surface. 
     
     
         12 . The method of  claim 11 , wherein the dispersing further comprises directing the metallic powder particles within the mixture solution toward the non-horizontal surface. 
     
     
         13 . The method of  claim 1 , wherein an average particle size of the metallic powder particles in the mixture solution is between 0.1-20 micrometers. 
     
     
         14 . The method of  claim 1 , wherein the metallic powder particles comprise a mass fraction of between 30-70% for the composite electroformed component. 
     
     
         15 . The method of  claim 1 , wherein the metallic powder particles comprise a volume fraction of between 30-70 vol % for the composite electroformed component. 
     
     
         16 . The method of  claim 1 , wherein the composite electroformed component comprises a thickness between 0.5-10 mm. 
     
     
         17 . A system for electroforming a component, comprising:
 an electroforming tank;   a cathode located within the electroforming tank;   a power source electrically coupled to the cathode; and   a mixture solution within the electroforming tank comprising an electrolytic solution with dispersed metallic powder particles therein, the metallic powder particles having an average particle size between 1-1000 micrometers.   
     
     
         18 . The system of  claim 17 , further comprising a set of flow controllers located within the electroforming tank and configured to agitate the mixture solution. 
     
     
         19 . The system of  claim 18 , wherein the set of flow controllers comprises at least one of an ultrasonic device emitting ultrasonic pressure waves into the mixture solution, a liquid pump emitting a liquid jet into the mixture solution, or an air pump emitting an air jet into the mixture solution. 
     
     
         20 . The system of  claim 19 , further comprising a dissolution tank having an anode electrically coupled to the power source, wherein the dissolution tank is fluidly coupled to the electroforming tank by at least one fluid conduit.