Cold spray system with variable tailored feedstock cartridges

Patent metadata

Field	Value
Publication number	US-10226791-B2
Application number	US-201715405970-A
Country	US
Kind code	B2
Filing date	Jan 13, 2017
Priority date	Jan 13, 2017
Publication date	Mar 12, 2019
Grant date	Mar 12, 2019

Abstract

A feedstock cartridge for a cold spray system including at least one powder; and a binder that interconnects at least two particles of the at least one powder.

First claim

The invention claimed is:

1. A cold spray system, comprising:
a material feed hopper to receive a feedstock cartridge of at least one powder and a binder;
a desolidifier downstream of the material feed hopper to at least partially desolidify a portion of the feedstock cartridge;
a heater downstream of the desolidifier to receive the portion of the feedstock cartridge and vaporize the binder; and
a spray gun downstream of the heater to spray the at least one powder.

2. The system as recited in claim 1 , wherein the desolidifier includes an auger that grinds off a portion of the feedstock cartridge.

3. The system as recited in claim 1 , wherein the desolidifier includes a laser that melts away at the feedstock cartridge.

4. The system as recited in claim 3 , wherein the laser is operable to vaporize the binder.

5. The system as recited in claim 1 , wherein the material feed hopper includes a feed mechanism to drive the feedstock cartridge toward the desolidifier.

6. The system as recited in claim 1 , wherein the heater includes a heated coil to vaporize the binder.

7. The system as recited in claim 1 , wherein the at least one powder is communicated from the spray gun in particles that are from 5 to 500 micrometers (μιη) in diameter at velocities from 300 to 1200 meters/second, and at a temperature of between 100-500° C.

8. The system as recited in claim 1 , wherein the binder is at least one of a wax, Polyvinylpyrrolidone (PVP), Poly(vinyl alcohol) (PVOH, PVA, or PVAl).

9. The system as recited in claim 1 , wherein the binder vaporizes at less than about 150 degree C.

10. The system as recited in claim 1 , wherein the binder completely covers each particle of the at least one powder.

11. The system as recited in claim 1 , wherein the binder partially covers each particle of the at least one powder.

12. The system as recited in claim 1 , wherein the feedstock cartridge includes a multiple of powders.

13. The system as recited in claim 12 , wherein each of the multiple of powders are intermixed in at least one layer defined by the feedstock cartridge.

14. The system as recited in claim 12 , wherein one of the multiple of powders form a gradient from a first end of the feedstock cartridge to an opposite end of the feedstock cartridge.

15. The system as recited in claim 12 , wherein at least one of the multiple of powders is a peening material.

Assignees

• United Technologies Corp

Inventors

• Dardas Zissis A
• Nardi Aaron T
• She Ying

Classifications

• B22F1/0062

  Operations & Transport · mapped topic

• B05B7/1686

  involving vaporisation of the material to be sprayed or of an atomising-fluid-generating product · CPC title

• C23C24/085

  Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides · CPC title

• B05B7/22

  electrically {, magnetically or electromagnetically}, e.g. by arc {(B05B7/20 takes precedence)} · CPC title

• C23C24/04

  Impact or kinetic deposition of particles · CPC title