WE CLAIM
1. A method of making a hollow metal component comprising the steps of:
providing at least one core comprising a first side and a reverse side;
utilizing a first metal spray process to apply at least one metal or metal alloy to said first side of said core, resulting in a partially-formed structure comprising a first side and a reverse side;
utilizing a second metal spray process to apply at least one metal or metal alloy to the reverse sides of said partially-formed structure and said core, resulting in a rough structure.
2. The method of claim 1, further comprising the initial step of providing a forming tool then providing said at least one core with said reverse side being in contact with said tool.
3. The method of claim 2, further comprising the step of removing said tool from said partially-formed structure while retaining said core within said partially-formed structure, thereby exposing the respective reverse sides of said partially-formed structure and said core.
4. The method of claim 1, wherein a plurality of cores are provided in spaced relation to one another and at least one metal or metal alloy is applied between said plurality of cores.
5. The method of Claim 1, wherein said rough structure is subjected to a densification process.
6. The method of claim 1 further comprising a step for removing said core.
7. The method of claim 6 wherein said cores are removed after said densification process.

8. The method of claim 1 further comprising hermetically sealing said tool, said core, or combinations thereof before utilizing said first metal spray process.
9. The method of claim 1 wherein a plurality of metals, metal alloys, or combinations thereof are utilized in said first metal spray process.
10. The method of claim 1 wherein a plurality of metals, metal alloys, or combinations thereof are utilized in said second metal spray process.
11. The method of claim 1 further comprising a step for finish machining said rough structure.
12. A hollow metal component comprising:
a first side having interior and exterior surfaces;
a reverse side having interior and exterior surfaces;
the interior surfaces of said first side and said reverse side defining at least one cavity;
wherein said component is integrally formed; and
wherein said component comprises regions comprising relatively different material compositions, said regions having gradual transitions of materials therebetween.
13. The hollow metal component of claim 12 comprising an airfoil shape having a leading edge, a trailing edge.
14. The hollow metal component of claim 12, further comprising at least one web extending between said interior surfaces.
15. The hollow metal component of claim 12 comprising a very fine grained microstructure.

16. The hollow metal component of claim 12 comprising a plurality of webs extending between said interior surfaces.
17. The hollow metal component of claim 12 wherein said component is selected from the group consisting of an outlet guide vane, a fan blade, a metal leading edge of a fan blade, and a strut.
18. The hollow metal component of claim 12 further comprising a plurality of cavities.
19. The hollow metal component of claim 12, wherein said component has at least 2 regions of different material compositions.
20. The hollow metal component of claim 12, wherein said component has a lightweight material in said cavity.