Methods for cold spray repair

Patent metadata

Field	Value
Publication number	US-10099322-B2
Application number	US-201314066443-A
Country	US
Kind code	B2
Filing date	Oct 29, 2013
Priority date	Oct 29, 2012
Publication date	Oct 16, 2018
Grant date	Oct 16, 2018

Abstract

Methods for aircraft component repair and reclamation are provided. Cold spraying aircraft panels include identifying a fastener hole in an aircraft panel in need of repair, capturing the location of the fastener hole, and depositing cold spray material about the fastener hole for reclaiming the aircraft panel. Any excess material may be removed. Cold spraying hydraulic lines includes identifying a surface of the hydraulic line in need of repair, aiming a cold spray nozzle at the surface of the hydraulic line and depositing a cold spray material on the surface of the hydraulic line. Excess cold spray material may be removed as needed.

First claim

What is claimed is:

1. A method for cold spraying metal aircraft panels comprising:
providing:
a cold spray system comprising an enclosed dry powder source housing a dry powder, a gas source for a gas and an accelerant, and a mixing manifold, wherein the enclosed powder source has a gas source input connected in operable communication with a gas line having a gas line pressure for receiving the gas from the gas source;
a gas-powder line operably connected to the dry powder source, the gas source and the mixing manifold;
a gas-powder mixture outlet connected in operable communication with the gas-powder line for receiving a gas-powder mixture from within the enclosed dry powder source, wherein the gas source input and the gas-powder mixture outlet operate at the gas line pressure using the gas from the gas source;
an accelerant line carrying the accelerant from the gas source and operably connected to the gas source and the mixing manifold;
a cold spray gun assembly consisting of a gas-powder-accelerant mixture hose having a hose length for carrying a gas-powder-accelerant mixture a distance from the mixing manifold, an input end operably connected to the mixing manifold and an output end operably connected to a cold spray gun, wherein the cold spray gun is positionable away from the mixing manifold by extending the hose length;

identifying a worn fastener hole in metal aircraft panel in need of repair, wherein the metal aircraft panel has opposite top and bottom surfaces and at least one axis of curvature following a contour of the aircraft and the worn fastener hole extends through the top and bottom surface and includes a chamfered surface formed during fabrication of the metal aircraft panel, and wherein as a result of use of the metal aircraft panel the worn fastener hole and chamfered surface include one or more dimensions outside original manufacturer dimensions and tolerances;
capturing a location of the worn fastener hole;
moving the cold spary gun into position adjacent the worn fastener hole without moving the mixing manifold;
orienting a nozzle of a cold spray gun assembly at the worn fastener hole generally perpendicular to the chamfered surface;
communicating the gas-powder-accelerant mixture from the mixing manifold through the gas-powder-accelerant mixture hose to an input side of the cold spray gun assembly;
depositing cold spray material about the worn fastener hole and chamfered surface to replace metal worn away from use of the metal aircraft panel; and
removing any excess cold spray material from the worn fastener hole and chamfered surface for matching the original manufacturer dimensions and tolerances.

2. The method of claim 1 further comprising:
recutting a chamfer into the fastener hole by removing deposited cold spray material.

3. The method of claim 1 further comprising at least one of:
a. preparing the fastener hold for cold spray adherence;
b. grinding the cold spray material flush with the metal aircraft panel;
c. repainting the metal aircraft panel.

4. The method of claim 1 wherein the metal aircraft panel further comprises a separate inner composite layer.

5. The method of claim 1 further comprising:
directing cold spray deposition by:
a. hand;
b. automation.

6. The method of claim 1 wherein the metal aircraft panel and cold spray material are aluminum.

7. A method for cold spraying hydraulic lines comprising:
providing:
a cold spray system comprising a dry powder source housing a dry powder, a gas source for a gas and an accelerant, and a mixing manifold, wherein the powder source has a gas source input connected in operable communication with a gas line having a gas line pressure for receiving the gas from the gas source;
a gas-powder line operably connected to the dry powder source for receiving the dry powder, the gas source for receiving the gas and the mixing manifold for receiving a gas-powder mixture;
a gas-powder mixture outlet connected in operable communication with the gas-powder line for receiving a gas-powder mixture from within the dry powder source, wherein the gas source input and the gas-powder mixture outlet operate at the gas line pressure using the gas from the gas source;
an accelerant line carrying the accelerant from the gas source and operably connected to the gas source and the mixing manifold;
a cold spray gun assembly consisting of a gas-powder-accelerant mixture hose having a hose length for carrying a gas-powder-accelerant mixture from the mixing manifold a distance from the mixing manifold through the hose length, an input end operably connected to the mixing manifold and an output end operably connected to a cold spray gun, wherein the cold spray gun is positionable away from the mixing manifold and in close proximity to hydraulic line by extending the hose length;

identifying a surface of a hydraulic line in need of repair;
aiming the cold spray gun at the surface of the hydraulic line;
depositing cold spray material onto the surface of the hydraulic line; and
removing any excess cold spray material.

8. The method of claim 7 further comprising:
reclaiming the hydraulic line in situ.

9. The method of claim 7 wherein the hydraulic line comprises an aircraft hydraulic line.

10. The method of claim 7 further comprising:
carrying the gas-powder-accelerant mixture through the gas-powder-accelerant mixture hose to the cold spray gun from a location of the dry powder source and gas source to a separate location proximate the hydraulic line.

11. The method of claim 7 further comprising:
articulating the cold spray gun by:
a. hand;
b. automation.

12. The method of claim 7 further comprising:
mobilizing the method for making an in situ repair to the hydraulic line.

13. A cold spray repair method comprising:
providing a cold spray system consisting of a dry powder source housing a dry powder, a gas source for a gas and an accelerant, and a mixing manifold, wherein the dry powder source has a gas source input connected in operable communication with a gas line from the gas source having a gas line pressure controlled by a gas controller for receiving the gas from the gas source at the gas line pressure;
a gas-powder line operably connected to the dry powder source, the gas source and the mixing manifold;
a gas-powder mixture outlet connected in operable communication with the gas-powder line for receiving a gas-powder mixture from within the dry powder source, wherein the gas source input and the gas-powder mixture outlet operate at the gas line pressure using the gas from the gas source;
an accelerant line carrying the accelerant from the gas source and operably connected to the gas source and the mixing manifold;
a cold spray gun having a gas-powder-accelerant mixture hose having a hose length for carrying a gas-powder-accelerant mixture a distance from the mixing manifold, an input end operably connected to the mixing manifold and an output end operably connected to a cold spray gun, wherein the cold spray gun is positionable away from the mixing manifold by extending the hose length;
heating the gas from the gas source;
moving the dray powder from the powder source through the gas-powder line at a pressure above atmospheric pressure;
mixing the heated gas and the dry powder creating a heated gas-powder mixture;
combining upstream before the input side of the spray gun assembly the heated gas-powder mixture with the accelerant from the gas source;
communicating the gas-powder-accelerant mixture together through the gas-powder-accelerant mixture hose to the input side of the cold spray gun; and
discharging the gas-powder-a

Assignees

• Widener Christian
• Well Adam
• Britton Owen
• James Brian
• Hrabe Rob
• Champagne Victor
• South Dakota Board Of Regents
• Us Army

Inventors

• Widener Christian
• Well Adam
• Britton Owen
• James Brian
• Hrabe Rob
• Champagne Victor

Classifications

• B23P6/00 Primary

  Restoring or reconditioning objects (straightening or restoring form of sheet metal, metal rods, metal tubes, metal profiles, or specific articles made therefrom B21D1/00, B21D3/00; repairing defective or damaged objects by casting techniques B22D19/10) · CPC title

• Y10T29/49748

  by shaping, e.g., bending, extruding, turning, etc. · CPC title

• C23C24/04

  Impact or kinetic deposition of particles · CPC title

• Y10T29/49746

  by applying fluent material, e.g., coating, casting · CPC title

• B64F5/40

  Maintaining or repairing aircraft · CPC title