Additive-based electroforming manufacturing methods and metallic articles produced thereby

Abstract

Additive-based electroforming manufacturing methods for producing turbomachine components and other metallic articles are provided, as are metallic articles manufactured utilizing such manufacturing methods. In various embodiments, the method includes the step or process of additively manufacturing a sacrificial tooling structure having a component-defining surface region. A metallic body layer or shell is deposited over the component-defining surface region utilizing an electroforming process such that a geometry of the component-defining surface region is transferred to the body layer. The tooling structure is chemically dissolved, thermally decomposed, or otherwise removed, while the metallic body layer is left substantially intact. After tooling structure removal, the metallic body layer is further processed to complete fabrication of the metallic component. In certain implementations, the method may further include the step or process of depositing an electrically-conductive base coat over the component-defining surface region of the tooling structure for usage in the subsequently-performed electroforming process.

What is claimed is: 
     
         1 . A metallic component, comprising:
 a plated body layer;   a central void surrounded by the plated body layer; and   an opening formed in the plated body layer through which the central void is exposed from an exterior of the metallic component,   wherein the metallic component is predominately composed of the plated body layer by volume percentage.   
     
     
         2 . The metallic component of  claim 1 , further comprising an electrically-conductive coating layer lining interior surfaces of the plated body layer defining the central void. 
     
     
         3 . The metallic component of  claim 2 , wherein the electrically-conductive coating layer is composed of an alloy predominately composed of aluminum by weight percentage. 
     
     
         4 . The metallic component of  claim 2 , wherein the electrically-conductive coating layer is configured to form a coating on the plated body layer. 
     
     
         5 . The metallic component of  claim 2 , wherein the electrically-conductive coating layer is configured to form a bond coat, and an additional coating layer is deposited over the electrically-conductive coating layer. 
     
     
         6 . The metallic component of  claim 1 , further comprising an airfoil portion defined, at least in substantial part, by the plated body layer;
 wherein the central void comprises an internal cavity surrounded by the airfoil portion, as taken about a longitudinal axis of the airfoil portion; and   wherein the opening is formed inboard or outboard of the airfoil portion, as taken along the longitudinal axis of the airfoil portion.   
     
     
         7 . The metallic component of  claim 6 , wherein the airfoil portion is associated with a nozzle vane. 
     
     
         8 . The metallic component of  claim 6 , wherein the airfoil portion is associated with a turbine blade. 
     
     
         9 . A metallic component, comprising:
 a plated body layer;   a central void surrounded by the plated body layer;   an electrically-conductive coating layer lining interior surfaces of the plated body layer defining the central void; and   an opening formed in the plated body layer through which the central void is exposed from an exterior of the metallic component,   wherein the metallic component is predominately composed of the plated body layer by volume percentage.   
     
     
         10 . The metallic component of  claim 9 , wherein the electrically-conductive coating layer is composed of an alloy predominately composed of aluminum by weight percentage. 
     
     
         11 . The metallic component of  claim 9 , wherein the electrically-conductive coating layer is configured to form a coating on the plated body layer. 
     
     
         12 . The metallic component of  claim 9 , wherein the electrically-conductive coating layer is configured to form a bond coat, and an additional coating layer is deposited over the electrically-conductive coating layer. 
     
     
         13 . The metallic component of  claim 9 , further comprising an airfoil portion defined, at least in substantial part, by the plated body layer;
 wherein the central void comprises an internal cavity surrounded by the airfoil portion, as taken about a longitudinal axis of the airfoil portion; and   wherein the opening is formed inboard or outboard of the airfoil portion, as taken along the longitudinal axis of the airfoil portion.   
     
     
         14 . The metallic component of  claim 13 , wherein the airfoil portion is associated with a nozzle vane. 
     
     
         15 . The metallic component of  claim 13 , wherein the airfoil portion is associated with a turbine blade.