Material deposition to form a sheet structure

Abstract

A method for forming a sheet structure includes providing a tool having a formation surface corresponding to a shape of the sheet structure. The method also includes depositing at least one layer of material on the formation surface using a cold-spray deposition technique. The method also includes removing the at least one layer of material from the formation surface to create the sheet structure.

1 . A system for forming a sheet structure, comprising:
 a tool having a formation surface corresponding to a desired shape of the sheet structure;   a cold-spray gun configured to output a gas including particles of a material towards the formation surface at a velocity sufficiently great to cause the particles of the material to bond together; and   a means for separating the material from the formation surface to create the sheet structure.   
     
     
         2 . The system of  claim 1 , wherein the sheet structure has a thickness between 5 thousandths of an inch (0.127 millimeters) and 1 inch (25.4 millimeters). 
     
     
         3 . The system of  claim 1 , further comprising a computer configured to generate a model of the tool. 
     
     
         4 . The system of  claim 3 , further comprising a robot configured to create the tool based on the model of the tool. 
     
     
         5 . The system of  claim 4 , further comprising an additive manufacturing machine, wherein the robot is configured to form the tool using the additive manufacturing machine. 
     
     
         6 . The system of  claim 1 , further comprising an electroplating machine configured to form an interface coating on the formation surface via electroplating, such that the particles of the material contact the interface coating on the formation surface. 
     
     
         7 . The system of  claim 1 , wherein the means for separating the material from the formation surface includes at least one of a mechanical tool usable to pry the material from the formation surface, a releasing agent configured to be applied between the material and the formation surface to separate the material from the formation surface, a heater configured to heat the formation surface to a sufficient temperature to separate the material from the formation surface, or an acid or other chemically reactive material configured to be applied to at least one of the material or the formation surface to etch the material from the formation surface. 
     
     
         8 . A sheet structure for use in an aircraft prepared by a method comprising the steps of:
 providing a tool having a formation surface corresponding to a shape of the sheet structure;   depositing at least one layer of material on the formation surface using a cold-spray deposition technique; and   removing the at least one layer of material from the formation surface to create the sheet structure.   
     
     
         9 . The sheet structure of  claim 8 , wherein the sheet structure has a thickness between 5 thousandths of an inch (0.127 millimeters) and 1 inch (25.4 millimeters). 
     
     
         10 . The sheet structure of  claim 8 , wherein the steps further include forming the tool via additive manufacturing, preparing a model of the tool using a computer, and controlling a robot to form the tool based on the model of the tool. 
     
     
         11 . The sheet structure of  claim 8 , wherein the steps further include forming an interface coating on the formation surface via electroplating, such that depositing the at least one layer of material includes depositing the at least one layer of material on the interface coating. 
     
     
         12 . The sheet structure of  claim 8 , wherein removing the at least one layer of material from the formation surface includes removing the at least one layer via at least one of applying physical force to the at least one layer of material in a direction away from the formation surface, applying a releasing agent between the at least one layer of material and the formation surface, increasing a temperature of the tool, or etching the at least one layer of material from the formation surface using an acid or other chemically reactive material. 
     
     
         13 . The sheet structure of  claim 8 , wherein the steps further include removing a portion of the formation surface of the tool to form a recess in the formation surface, wherein depositing the at least one layer of material on the formation surface further includes depositing a greater amount of material in the recess on the formation surface such that the sheet structure has a greater thickness at a location corresponding to the recess.