Cold spray method to join or in certain cases strengthen metals

Patent metadata

Field	Value
Publication number	US-10329033-B2
Application number	US-201615543269-A
Country	US
Kind code	B2
Filing date	Jan 13, 2016
Priority date	Jan 16, 2015
Publication date	Jun 25, 2019
Grant date	Jun 25, 2019

Abstract

A method of repairing or, in certain cases, strengthening a metallic substrate at a damage site is provided and includes removing material from the substrate around the damage site to form a recess, and cold spraying particulate material into the recess to form a bead of deposited material.

First claim

The invention claimed is:

1. A method of repairing or, in certain cases, strengthening a metallic substrate at a damage site, comprising:
removing material from the substrate around the damage site to form a recess having chamfered edges and rounded corners; and
cold spraying particulate material into the recess to form a bead of deposited material.

2. The method according to claim 1 , wherein a ratio of cross-sectional areas of the bead and the substrate is greater than a ratio of a strength of the substrate to a strength of the bead.

3. The method according to claim 1 , wherein a ratio of a total bond area between the bead and the substrate to the cross-sectional area of the substrate is greater than a ratio of the strength of the substrate to a bond strength between the bead and the substrate.

4. The method according to claim 1 , wherein the bead comprises rounded corners having a radius of at least 0.5 times an exit diameter of a nozzle from which the particulate material is cold sprayed.

5. The method according to claim 1 , further comprising machining the bead to planarize the bead.

6. The method according to claim 1 , further comprising machining the bead to smooth the bead.

7. The method according to claim 1 , further comprising:
clamping a doubler to the substrate at the damage site;
machining the doubler; and
machining the bead to planarize the bead.

8. The method according to claim 1 , wherein the removing of the material from the substrate comprises forming a tapered recess in the substrate.

9. The method according to claim 8 , wherein an angling of the recess is defined in accordance with a type of the particulate material and a velocity of the cold spraying.

10. An in situ method of repairing or, in certain cases, strengthening an aluminum substrate at a damage site, comprising:
removing material from the substrate around the damage site to form a tapered recess having chamfered edges and rounded corners and narrow and wide ends at first and second opposite sides of the substrate, respectively;
clamping a doubler to the first side of the substrate at the damage site; and
cold spraying particulate material into the recess against the doubler to form a bead.

11. The method according to claim 10 , further comprising inspecting the substrate to identify the damage site.

12. The method according to claim 10 , further comprising:
machining the doubler; and
machining the bead to planarize the bead.

13. The method according to claim 10 , wherein an angling of the chamfered edges is defined in accordance with a type of the particulate material and a velocity of the cold spraying.

Assignees

• Sikorsky Aircraft Corp

Inventors

• Choi Jinkyu
• Nardi Aaron T
• Klecka Michael A
• Guillemette Robert
• Mendoza Jeffrey Michael

Classifications

• F05D2230/10

  by removing material · CPC title

• B22F7/06

  of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} · CPC title

• B22F2007/068

  repairing articles · CPC title

• B23P2700/01

  Aircraft parts · CPC title

• Y02T50/672

  Cross-Sectional Technologies · mapped topic