ELECTROFORMING APPARATUS AND METHOD FOR FORMING A RIB

Abstract

Aspects of the disclosure generally relate to an electroforming apparatus and method, including a support frame with at least one anode housing having a predetermined housing geometry. At least one anode can be carried by the at least one anode housing, and the at least one anode can also include a predetermined geometry.

Description

BACKGROUND

An electroforming process can create, generate, or otherwise form a metallic layer or component. In one example of the electroforming process, a mold or base for the desired component can be submerged in an electrolytic solution and electrically charged. The electric charge of the mold or base can attract an oppositely-charged electroforming material through the electrolytic solution. The electric attraction of the electroforming material to the mold or base ultimately deposits the electroforming material onto the exposed surfaces mold or base, creating a metallic layer.

BRIEF DESCRIPTION

In one aspect, the disclosure relates to an electroforming apparatus. The electroforming apparatus can include a support frame with at least one anode housing having a predetermined housing geometry, and at least one anode carried by the at least one anode housing and having a predetermined anode geometry, the at least one anode being configured to electrically couple to a power source.

In another aspect, the disclosure relates to a system for electroforming a component. The system can include a fluid reservoir containing an electrolytic fluid, a substrate located within the fluid reservoir and defining a cathode, and at least one anode located within the fluid reservoir and spaced from the cathode, the at least one anode having a predetermined geometry configured to increase a local current density within the electrolytic fluid during electroforming such that a local deposition rate on the cathode is increased.

In yet another aspect, the disclosure relates to a method of forming a component. The method can include providing a substrate in a fluid reservoir containing an electrolytic fluid and at least one anode, electrically coupling the substrate to a power source such that the substrate is configured to form a cathode, and electroforming a stiffening rib of an isogrid pattern on the substrate, wherein a geometry of the at least one anode is configured to increase a local current density within the electrolytic fluid during electroforming such that a local deposition rate on the cathode is increased.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a turbine engine for an aircraft.

FIG. 2 is a perspective view of a portion of the turbine engine of FIG. 1 including an electroformed component in accordance with various aspects described herein.

FIG. 3 is a schematic view of an electrodeposition bath and electroforming apparatus that can be utilized to form the electroformed component of FIG. 2.

FIG. 4 is a cross-sectional view of one anode housing and anode that can be utilized in the electroforming apparatus of FIG. 3.

FIG. 5 is a schematic side view of the electroforming apparatus of FIG. 3 with the anode housing and anode of FIG. 4 in a first configuration during operation.

FIG. 6 is a schematic side view of the electroforming apparatus of FIG. 3 with the anode housing and anode of FIG. 4 in a second configuration during operation.

FIG. 7 is a cross-sectional view of another electroforming apparatus that can be utilized to form the electroformed component of FIG. 2.

FIG. 8 is a cross-sectional view of yet another electroforming apparatus that can be utilized to form the electroformed component of FIG. 2.

FIG. 9 is a cross-sectional view of still another electroforming apparatus that can be utilized to form the electroformed component of FIG. 2.

FIG. 10 is a flowchart illustrating a method of forming the electroformed component of FIG. 2.

DETAILED DESCRIPTION

Grid or isogrid geometries have been traditionally utilized to create high strength-to-weight panel and shell structures in aeronautics. Such geometries generally consistent of a series of interconnected ribs in a repeating pattern, such as patterns of triangles or rectangles with common corners. For fluid delivery components, such a grid geometry can have a continuous wall at the base of the ribs and can form a part of a pressure vessel. Other uses for the interconnected ribs are to locally increase wall strength in high stress locations or to provide a location for mounting brackets to the panel or shell without affecting wall integrity or strength.

Traditionally grid or isogrid geometries have been machined into the surface of plates or shells to reduce weight and increase strength and stiffness for a component during operation. However, such machining operations on curved or complex contour surfaces is expensive and limited to low-volume production of components.

Aspects of the present disclosure are directed to an electroforming apparatus, system, and method for electroforming at least a portion of a component. More specifically it is described herein the fabrication of lightweight high-temperature fluid delivery components with directly integrated isogrid regions via enhanced electrodeposition to produce locally strengthened complex geometries. For purposes of illustration, the present disclosure will be described in the context of isogrid regions in an aircraft turbine engine. It will be understood, however, that the disclosure is not so limited and may have general applicability, including in forming geometries in non-aircraft applications such as other mobile applications and non-mobile industrial, commercial, and residential applications.

As used herein, the term “forward” or “upstream” refers to moving in a direction toward the engine inlet, or a component being relatively closer to the engine inlet as compared to another component. The term “aft” or “downstream” used in conjunction with “forward” or “upstream” refers to a direction toward the rear or outlet of the engine or being relatively closer to the engine outlet as compared to another component. As used herein, “a set” can include any number of the respectively described elements, including only one element. All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the disclosure. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

An exemplary turbine engine 10 is illustrated in FIG. 1. The turbine engine 10 can be a gas turbine engine, including a turbofan, turboprop, or turboshaft engine in non-limiting examples. The turbine engine 10 includes, in downstream serial flow relationship, a fan section 18 including a fan 20, a compressor section 22 including a booster or low pressure (LP) compressor 24 and a high pressure (HP) compressor 26, a combustion section 28 including a combustor 30, a turbine section 32 including a HP turbine 34, and a LP turbine 36, and an exhaust section 38.

The fan section 18 includes a fan casing 40 surrounding the fan 20. The fan 20 includes a plurality of radially-disposed fan blades 42. The HP compressor 26, the combustor 30, and the HP turbine 34 form a core 44 of the engine 10, which generates combustion gases. The core 44 is surrounded by core casing 46, which can be coupled with the fan casing 40. The compressor section 22 provides the combustor 30 with high pressure air. The high pressure air is mixed with fuel and combusted in the combustor 30. The hot and pressurized combustion gases pass through the HP turbine 34 and LP turbine 36 before exhausting from the turbine engine 10.

As the pressurized gases pass through the compressor section 22, the turbines 34, 36 extract rotational energy from the flow of the gases passing through the turbine engine 10. The HP turbine 34 can be coupled to a compression mechanism (not shown) of the compressor section 22 by way of a shaft to power the compression mechanism. The LP turbine 36 can be coupled to the fan 20 by way of a shaft to power the fan 20. Optionally, the turbine engine 10 can also have an afterburner that burns an additional amount of fuel downstream of the turbine section 32 to increase the velocity of the exhausted gases, thereby increasing thrust.

FIG. 2 illustrates a portion of the core casing 46 including interior portions thereof such as a plurality of stiffening ribs 60 which, while illustrated on the core casing 46, can be included in any suitable location on or within the engine 10 including the core casing 46, fan casing 40, turbine section 32 and exhaust section 38 as desired. The stiffening ribs 60 can provide additional structural strength for the engine 10 and components therein during operation.

The stiffening ribs 60 can have any suitable geometric profile or cross-section, and can also be arranged in any desired pattern or form. For example, an isogrid pattern can be utilized wherein the stiffening ribs 60 are connected over a base sheet 55 forming an interior portion of the core casing 46. It is also contemplated that multiple base sheets 55 can be connected to form the interior portion of the core casing 46. In the example shown, first stiffening ribs 61 are arranged to form a triangular isogrid pattern over the base sheet 55. Second stiffening ribs 62 are arranged to form a rectangular grid pattern over the base sheet 55. Third stiffening ribs 63 are arranged with a triangular isogrid pattern interspersed with local connections 65 coupling or connecting the stiffening ribs 63 over the base sheet 55. It should be understood that the stiffening ribs 61, 62, 63 are exemplary and that any geometrical arrangement of the stiffening ribs 60 can be utilized. Generally, size, rib geometry, and extent of stiffening rib pattern will be tuned for the specific stress distribution, component size, and local geometry.

FIG. 3 illustrates a system 70 for electroforming a component or a portion of a component, such as the stiffening ribs 60. A fluid reservoir 72 containing an electrolytic fluid 74, such as nickel alloy carrying alloying metal ions in a non-limiting example, can be included in the system 70. A component having a substrate 76 is located within the fluid reservoir 72 to define a cathode 78. It will be understood that the component in the above described example would be an interior portion of the core casing 46 with the base sheet 55 forming the substrate 76. In this manner it will be understood that the substrate 76 can be a curved portion of a pressure vessel such as the core casing 46 although only a portion of a curved surface is shown. The substrate 76 can include any suitable material, including metal or composite materials. It is also contemplated that a conductive spray or similar treatment can be provided to the substrate 76 to facilitate formation of the cathode 78. Further still, to limit deposition of metal it will be understood that any portion of the substrate can be masked, etc.

An electroforming apparatus 80 having a support frame 81 with at least one anode housing 84 can also be included in the system 70. In the illustrated example, two anode housing(s) 84 are illustrated projecting from a frame base 82 of the support frame 81. It will be understood that any suitable number of anode housings 84 can be included. The anode housing(s) 84 can be operably coupled or integrally formed with the support housing 82 in any suitable manner. The support frame 81 including the anode housing(s) 84 can optionally include a non-conductive material such as ABS plastic formed by additive manufacturing in one non-limiting example.

At least one anode 86 can be carried by a corresponding at least one anode housing 84 of the support frame 81. More specifically, the anode housing 84 can include an outer housing surface or tip 97 configured to carry the anode 86. The anode 86 can include a non-consumable or non-sacrificial anodic material, and titanium is contemplated for use in a non-limiting example. In the illustrated example, two anode housings 84 and two anodes 86 are provided and spaced apart from each other as well as being spaced apart from the cathode 78 within the fluid reservoir 72. It should be understood that the electroforming apparatus 80 in the system 70 can include any number of anodes or anode housings, including that multiple anodes can be carried by a single tip of the anode housing.

An additional anode 77 can also be provided in the fluid reservoir 72. The additional anode 77 can be a consumable or sacrificial anode, such as nickel or cobalt coins within a titanium mesh container or anode basket in one non-limiting example. The additional anode 77 can provide ions to replenish the electrolytic fluid 74 during operation.

A controller 88, which can include a power source, can electrically couple to the anodes 86 and the cathode 78 by electrical conduits 90 to form a circuit via the electrolytic fluid 74. Optionally, a switch 92 or sub-controller can be included along the electrical conduits 90, between the controller 88 and the anodes 86 and cathode 78. It will be understood that the electrical conduit 90 will run through the support frame 81 and anode housing(s) 84 as necessary to couple to the anode(s) 86. In an alternate example (not shown), a separate power supply with a control switch can be connected to the additional anode 77. In still another example (not shown), the anode 86 and additional anode 77 can be connected in parallel to the controller or power source 88, with separate control switches provided for each of the anode 86 and additional anode 77.

It is further contemplated that the support frame 81 can be moveable within the fluid reservoir 72. For example, the support frame 81 can be translated vertically as indicated by the arrow 101 or horizontally at least as indicated by the arrow 103, or any combination thereof. Alternatively or additionally, it will be understood that the at least one anode housing 84 can be moved within the support frame 81 such that in effect it is moved with respect to the substrate 76. Alternatively or additionally, it will be understood that the component or substrate 76 can be moveable within the reservoir 72.

During operation, a current can be supplied from the anode(s) 86 to the cathode 78 to electroform a protrusion 89 on the substrate 76. The protrusion 89 can at least partially define an elongated stiffening rib 60. In the example shown, multiple elongated stiffening ribs 60 are formed over the curved substrate 76. During supply of the current, metal alloys from the electrolytic fluid 74 form a metallic layer over the substrate 76 to form at least a portion of the protrusion 89 (e.g. at least a portion of the stiffening ribs 60). The number of stiffening rib(s) 60 formed in the illustrated example corresponds directly to the number of anode(s) 86. In one example, each anode 86 can be utilized to electroform individual stiffening ribs 60 over the substrate 76. In another example, multiple anodes 86 can be utilized to electroform different portions of the same stiffening rib 60. In still another example, multiple anodes 86 can be utilized to form a stiffening rib.

Turning to FIG. 4, a portion of the anode housing 84 is shown carrying the anode 86. A fluid channel 83 can be provided through the anode housing 84 such that electrolytic fluid 74 (FIG. 3) can flow through the fluid channel 83 and onto the substrate 76 (FIG. 3). In the example shown, two fluid channels 83 are provided on either side of the anode 86 although any number of fluid channels 83 can be provided at any suitable location(s) and angle(s). For example, the electrolytic fluid 74 can be pumped (not shown) or otherwise supplied from the fluid reservoir 72 to an outer housing surface or tip 97 of the anode housing 84. The fluid channel 83 can also have any suitable width or position within the anode housing 84. In this manner, the support frame 81 can be further configured to provide electrolyte jets from the support frame 81, such as toward the substrate 76 (FIG. 3).

It is contemplated that the anode housing 84, such as the tip 97, can have a predetermined housing geometry (herein “housing geometry”) 85. The anode 86 can have a predetermined anode geometry (herein “anode geometry”) 87. The tip 97 can be complementary to at least a portion of the anode geometry 87. In the illustrated example, the housing geometry 85 is rectangular with a flat interior housing surface 91, and the anode geometry 87 is rectangular with a flat inner anode surface 93 and a flat outer anode surface 94. The anode 86 can further include sidewalls 95 extending between the inner and outer anode surfaces 93, 94 and forming a length 96 of the anode 86.

It is further contemplated that the support frame 81 can surround at least a portion of the anode 86. For example, the anode housing 86 can extend along at least a portion of at least one sidewall 95. It is also contemplated that the support frame 81 can extend distally beyond the anode 86. More specifically, the anode housing 84 of the support frame 81 extends distally beyond the sidewall 95 of the anode 86.

Additionally, the anode housing 184 can be configured to reduce electric field edge effects at the anode 86, including at the sidewalls 95 of the anode 86. In one example, by at least partially surrounding the conductive anode 86 with the non-conductive anode housing 84, portions of the electric field proximate the sidewalls 95 can be insulated, reduced, or redirected as compared to an electric field near an exposed anode.

Referring now to FIG. 5, the system 70 is illustrated during an electroforming operation. The system 70 is illustrated utilizing the anode housing 84 and anode 86 as described above, and it will be understood that the described aspects can be applied to any anode housing, housing geometry, anode, or anode geometry. However for exemplary purposes, a configuration is shown wherein the anode housing 84 and anode 86 are positioned within the fluid reservoir 72 (FIG. 3). The anode 86 is spaced apart by a first distance 120 from the substrate 76 that forms the cathode 78. Current can be supplied to the anode 86 and the substrate 76 to deposit metal alloys and electroform a stiffening rib 60.

The substrate 76 is illustrated as being flat for clarity, and it will be understood that the substrate 76 can have a curved geometry or curved surface as described above. In addition, the anode housing 84, anode 86, and substrate 76 are shown in cross-section with hatching lines omitted for visual clarity.

Electrolytic fluid 74 can move through the fluid channel 83, such as in the form of electrolyte jets at any velocity, and impinge the substrate 76. Exemplary current density streamlines 105 are shown extending from the anode 86 to the cathode 78 along which ions from the electrolytic fluid 74 can move. The current density streamlines 105 indicate an amount of charge per unit area. The spacing between adjacent current density streamlines 105 can be a visual indicator of an amount of current density in a given region, wherein large current densities are represented by closely-packed current density streamlines. It should be understood that a given current density streamline also points in the same direction as an electric field line at that location, wherein the line direction indicates a direction of motion for an exemplary positive charge between an anode and cathode.

The predetermined anode geometry 87 can be configured in relation to the cathode 78 to effect a local current density within the electrolytic fluid 74 during electroforming. More specifically, a first region 111 of the electrolytic fluid 74 is shown having a higher local current density, as indicated by a high concentration of current density streamlines 105. A second region 112 is shown having a lower local current density, as indicated by a low concentration of current density streamlines 105. Such differing local current densities in the first and second regions 111, 112 can be generated as a result of the predetermined anode geometry 87, and a resulting deposition rate in the first region 111 can be greater than in the second region 112. Formation of the stiffening rib 60 with the first height 122 can result from the selected first distance 120, the locally-increased deposition rate, and locally-increased current density in the first region 111 as compared to the second region 112. It is also contemplated that the impingement of electrolytic fluid 74 can form the stiffening rib 60 with any suitable height-to-width ratio, such as 1:1 in a non-limiting example.

In addition, the anode housing 84 can reduce or insulate electric field edge effects near the sidewalls 95. This can have an effect of directing the current density streamlines downward, further increasing the local current density in the first region 111 and further reducing the local current density in the second region 112 or other regions further away from the anode 87.

The concentration of current density streamlines 105 and deposition rate onto the cathode 78 can also be increased or customized based on the spacing, such as the first distance 120, between the anode 86 and cathode 78. It can be appreciated that decreasing a spacing distance between the anode 86 and cathode 78 can increase a local deposition rate on the cathode 78, for example.

The electroforming can continue until the stiffening rib 60 has a first height 122 and a first width 124. The first height 122 is defined between the substrate 76 and a peak of the stiffening rib 60. The first width 124 can, in one example, represent a “full width at half maximum” (FWHM) width of the stiffening rib 60. In addition, while the stiffening rib 60 is shown with a curved geometric profile near its peak, other geometries are contemplated for use including squared with a flattened peak. In addition, a gap 115 is defined between the stiffening rib 60 and the anode 86.

FIG. 6 illustrates a second configuration of the system 70 during the electroforming operation. It is contemplated that during electroforming, the anode housing 84 can move vertically upward to a second distance 130 from the substrate 76. For example, the gap 115 can be maintained between the anode 86 and the stiffening rib 60 during the electroforming process such that as the stiffening rib 60 grows in height, the support frame 81 (FIG. 4) and anode housing 84 is moved or translated away from the substrate 76 to maintain the relatively constant gap 115. As used herein, a “relatively constant” gap will refer to a gap that does not vary over time by more than a predetermined limit. In one example the predetermined limit can be relative, such as 10% of the initial gap or smaller. In another example the predetermined limit can be an absolute limit, such as 1 cm or smaller. In still another example the predetermined limit can be based on another parameter of the system 70, such as a gap not larger than the second width 134 of the stiffening rib 60.

The anode geometry 87 can continue to provide a higher local current density in the first region 111 proximate the stiffening rib 60 such that the stiffening rib 60 experiences a locally-higher deposition rate in the first region 111 as compared to the second region 112. Motion of the anode housing 84 can form the stiffening rib 60 with a second height 132 and a second width 134. It is further contemplated that a height-to-width ratio in the second configuration can be greater than 1:1, including due to the motion of the anode housing 84 away from the substrate and the shape of the anode 86 to increase current density flux in the region of the tip width to control and concentrate material deposition. Additionally, a rate of electrolytic fluid flow through the fluid channel 83 can be increased or decreased to modify a local deposition rate at the cathode 78. In this manner, the stiffening rib 60 can be electrodeposited in situ over the curved substrate 76 by way of the electroforming apparatus 80 (FIG. 3).

FIG. 7 illustrates a portion of an electroforming apparatus 180 similar to the electroforming apparatus 80. Like parts will be identified with like numerals increased by 100, with it being understood that the description of the like parts of the electroforming apparatus 80 applies to the electroforming apparatus 180, except where noted.

The electroforming apparatus 180 includes an anode housing 184 included in or part of a support frame 181 with a fluid channel 183 and carrying an anode 186 similar to the anode 86 described above. The anode 186 can have a rectangular anode geometry 187, and the anode housing 184 can have a rectangular housing geometry 185. One difference is that the anode housing 86 extends along a portion of both sidewalls 195, and the outer anode surface 194 extends distally beyond the anode housing 186. In this manner the anode 186 can fit within, and be carried by, the anode housing 184. It can also be appreciated that extending the anode 86 beyond the anode housing 186 can increase a local electric field and current density by positioning the anode 186 closer to the stiffening rib 60 during electroforming.

FIG. 8 illustrates a portion of an electroforming apparatus 280 similar to the electroforming apparatus 80. Like parts will be identified with like numerals increased by 200, with it being understood that the description of the like parts of the electroforming apparatus 80 applies to the electroforming apparatus 280, except where noted.

The electroforming apparatus 280 includes an anode housing 284 included in or part of a support frame 281 with a fluid channel 283 and carrying an anode 286 similar to the anode 86 described above. One difference is that in the illustrated example, the anode housing 284 has a concave V-shaped housing geometry 285 with a V-shaped interior housing surface 291. The anode 286 can have a convex V-shaped anode geometry 287, including a V-shaped inner anode surface 293, which is complementary to the housing geometry 285. Another difference is that the anode 286 includes an outer anode surface 294 that is flush or aligned with a tip 297 of the anode housing 284. In this example, neither the anode 286 nor the anode housing 284 extend distally beyond one another. It is contemplated that the V-shaped anode geometry 287 can provide for further narrowing of a local electric field proximate the anode 286, where regions proximate the anode 286 have a higher local current density. Such field narrowing or concentrating can provide for the creation of a narrower, taller electroformed stiffening rib.

FIG. 9 illustrates a portion of electroforming apparatus 380 similar to the electroforming apparatus 80. Like parts will be identified with like numerals increased by 300, with it being understood that the description of the like parts of the electroforming apparatus 80 applies to the electroforming apparatus 380, except where noted.

The electroforming apparatus 380 includes an anode housing 384 included in or part of a support frame 381 with a fluid channel 383 and carrying an anode 386 similar to the anode 86 described above. One difference is that the anode 386 has a curved anode geometry 387 including a curved surface 393. The anode housing 384 has a tip 397 with a curved housing geometry 385 that includes a curved interior housing surface 391. The anode geometry 387 is complementary to the housing geometry 385 such that the anode 386 can fit within, and be carried by, the tip 397.

Another difference is that the curved surface 393 forms an entire outer surface of the anode 386 and defines a length 396 of the anode 386. The anode housing 384 extends and surrounds a portion of the anode 386, and the anode 386 can extend distally beyond the tip 397 of the anode housing 384 as shown.

It is contemplated that the curvature of the anode 386 can provide for narrowing of electric field and current density even as the anode 386 extends distally beyond the anode housing 384. Current density streamlines can extend from the curved anode 386 toward a stiffening rib during electroforming to define a more concentrated field at the stiffening rib location with a locally-higher current density.

FIG. 10 illustrates a method 400 of forming a component such as the stiffening rib 60. The method 400 includes, at 402, providing the substrate 76 in the fluid reservoir 72 containing electrolytic fluid 74 and at least one anode, such as the anode 86, 186, 286, or 386. At 404, the substrate 76 can be electrically coupled to a power source, such as the controller 88, such that the substrate 76 is configured to form the cathode 78. At 406, a stiffening rib of a grid or isogrid pattern, such as the first rib 61, second rib 62, or third rib 63 (FIG. 2), can be electroformed on the substrate 76.

Optionally, the method can include surrounding at least a portion of the non-sacrificial anode with a non-conductive support frame as described above. The method optionally can also include having the support frame 81 extend distally beyond a length of the anode as described above to aid in controlling current density flux. Optionally, the method 400 can also include electroforming a second portion of the stiffening rib 60 via the anode 86, 186, 286, or 386, as well as moving the tip of the anode 86, 186, 286, or 386 away from the substrate 76 to maintain a relatively constant gap 115 while forming the second portion of a stiffening rib 60 as described above. The method 400 can further optionally include providing a low-velocity impinging jet of electrolytes while electroforming. Additional stiffening ribs 60 can also be formed by the electroforming apparatus 80, including forming the stiffening ribs 60 in a grid or isogrid pattern, and a geometry of the stiffening ribs 60 can be modified at various locations to reduce weight. The method 400 can further optionally include determining strength requirements of the stiffening ribs 60, including any additional stiffening ribs, prior to electroforming and that the movement of the anode 86 and deposition of ribs can be based thereon.

Aspects of the present disclosure provide for a variety of benefits including integrates complex part geometry directly during the electrodeposition process as an in situ structural feature. The forming of grid or isogrid geometry directly during the electrodeposition process as an in situ structural feature provides for less material waste and lower costs of manufacturing. The anode with predetermined geometry can provide for the precise control of the direction and deposition of metal ions onto the substrate. Still another benefit is that the integration of electrolyte jets with the support frame can be utilized to tune local flow of electrolytic fluid, metal ion concentration, and diffusion boundary layer height. In addition to an impinging flow of electrolyte, the electric field distribution and associated current density lines provide for a customized distribution of deposited material. The geometry or cross-sectional shape of the anode, as well as the distance between anode and cathode, as well as insulative properties of the housing, can provide for a customized stiffening rib shape or isogrid pattern over the substrate.

To the extent not already described, the different features and structures of the various embodiments can be used in combination, or in substitution with each other as desired. That one feature is not illustrated in all of the embodiments is not meant to be construed that it cannot be so illustrated, but is done for brevity of description. Thus, the various features of the different embodiments can be mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described. All combinations or permutations of features described herein are covered by this disclosure.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. An electroforming apparatus, comprising:

a support frame with a frame base and at least one anode housing projecting from the frame base and having a predetermined housing geometry; and

at least one anode carried by a tip of the at least one anode housing and having a predetermined anode geometry, the at least one anode being configured to electrically couple to a power source.

2. The electroforming apparatus of claim 1 wherein at least a portion of the tip is complementary to at least a portion of the predetermined anode geometry.

3. The electroforming apparatus of claim 1 wherein at least one of the predetermined housing geometry or the predetermined anode geometry is at least one of flat, curved, or V-shaped.

4. The electroforming apparatus of claim 1 wherein the at least one anode comprises a non-sacrificial anodic material, and wherein the support frame comprises a non-conductive material.

5. The electroforming apparatus of claim 4 wherein the non-conductive material comprises plastic, and wherein the non-sacrificial anodic material comprises titanium.

6. The electroforming apparatus of claim 1 wherein the support frame surrounds at least a portion of the at least one anode.

7. The electroforming apparatus of claim 6 wherein the support frame extends along at least a portion of a sidewall of the anode forming a length of the anode.

8. The electroforming apparatus of claim 7 wherein the support frame extends distally beyond the sidewall of the anode.

9. The electroforming apparatus of claim 7 wherein the support frame is configured to reduce electric field edge effects at the sidewall of the anode.

10. The electroforming apparatus of claim 1 wherein the support frame houses two anodes spaced from each other.

11. A system for electroforming a component, comprising:

a fluid reservoir containing an electrolytic fluid;

a substrate located within the fluid reservoir and defining a cathode; and

an electroforming apparatus, comprising: a support frame with a frame base and at least one anode housing projecting from the frame base and having a predetermined housing geometry; and at least one anode carried by a tip of the at least one anode housing and having a predetermined anode geometry, the at least one anode being configured to electrically couple to a power source.

12. The system of claim 11, further comprising at least one anode housing coupled to a moveable support frame and having a predetermined anode geometry, wherein the at least one anode comprises a non-sacrificial anode carried by a tip of the at least one anode housing.

13. The system of claim 12 wherein the predetermined anode geometry is at least one of flat, curved, or V-shaped.

14. The system of claim 11 wherein the substrate is a curved portion of a pressure vessel and the system is configured to electroform a protrusion on the curved portion.

15. The system of claim 11, further comprising a non-conductive support frame surrounding at least a portion of the at least one anode.

16. The system of claim 15 wherein the non-conductive support frame is further configured to provide electrolyte jets toward the substrate.

17. The system of claim 15 wherein the non-conductive support frame is translatable at least vertically within the fluid reservoir.

18. A method of forming a component, the method comprising:

providing a substrate in a fluid reservoir containing an electrolytic fluid and at least one anode located within a corresponding at least one anode housing having a predetermined housing geometry;

electrically coupling the substrate to a power source such that the substrate is configured to form a cathode; and

electroforming a protrusion on the substrate;

wherein the at least one anode has a predetermined anode geometry configured in relation to the cathode to increase a local current density within the electrolytic fluid during electroforming such that a local deposition rate on the cathode is increased at the location of the protrusion.

19. The method of claim 18 wherein a spacing distance between the at least one anode and the cathode is configured to increase the local current density during electroforming such that at local deposition rate on the cathode is increased.

20. The method of claim 18 wherein a non-conductive support frame surrounds at least a portion of the at least one anode, and wherein the non-conductive support frame extends distally beyond a length of the at least one anode.

21. The method of claim 18 wherein the protrusion at least partially defines an elongated stiffening rib.

22. The method of claim 21, further comprising forming multiple stiffening ribs.

23. The method of claim 22 further comprising simultaneously forming the multiple stiffening ribs.

24. The method of claim 22 wherein the multiple stiffening ribs define an isogrid pattern.

25. The method of claim 21, further comprising electroforming a second portion of the stiffening rib via the at least one anode.

26. The method of claim 21, further comprising moving the anode away from the substrate to maintain a relatively constant gap while forming a second portion of a stiffening rib.

27. The method of claim 18, further comprising providing a low-velocity impinging jet of electrolytes during the electroforming.