Multi-component deposits

Patent metadata

Field	Value
Publication number	US-12378677-B2
Application number	US-202217657884-A
Country	US
Kind code	B2
Filing date	Apr 4, 2022
Priority date	Oct 18, 2019
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

Abstract

The disclosure describes an example technique that includes cold spraying first particles and second particles of a metal alloy on at least a portion of a surface of a substrate to form a deposit on the surface of the substrate. The first and second particles have been subjected to different heat treatments prior to cold spraying. Cold spraying involves accelerating the first particles and the second particles toward the surface of the substrate without melting or creating other thermally induced changes to a microstructure of the first and second particles. As a result, the first particles form a first, heat-treated component and the second particles form a second non-heat-treated or differently-heat-treated component, and the particles and substrate are not subject to a heat treatment during the cold spray process that may further modify their thermomechanical properties.

First claim

What is claimed is:

1. A method comprising:
cold spraying first particles and second particles of a same metal alloy on at least a portion of a surface of a substrate to form a deposit on the surface of the substrate,
wherein the first particles form a first component of the deposit and the second particles form a second component of the deposit,
wherein cold spraying comprises accelerating the first particles and the second particles toward the surface of the substrate at a temperature below a melting point and a transition temperature without melting and without creating other thermally induced changes to a microstructure of the respective first and second particles,
wherein the first and second particles have been subjected to different heat treatments prior to cold spraying,
wherein the first component and the second component are non-homogeneously distributed throughout the deposit,
wherein a tensile strength of the first particles is at least about 10% greater than a tensile strength of the second particles, and
wherein a percent elongation of the first particles is at least about 10% greater than a percent elongation of the second particles.

2. The method of claim 1 , wherein the first particles comprise at least one of precipitation hardened particles, quenched hardened particles, or tempered particles.

3. The method of claim 1 , wherein a volume percentage of the first component in the deposit is between about 1% and about 99%.

4. The method of claim 1 , wherein the metal alloy comprises at least one of a Mg-based alloy, a Ni-based alloy, a Ti-based alloy, a Fe-based alloy, an Al-based alloy, a Co-based alloy, a Ta-based alloy, a Nb-based alloy, a Zn-based alloy, a Cr-based alloy, or a Cu-based alloy.

5. The method of claim 1 , wherein the surface comprises a cracked surface, and wherein forming the deposit further comprises filling the cracked surface with the deposit.

6. The method of claim 1 , wherein a tensile strength of the first particles is at least about twice as high as a tensile strength of the second particles.

7. The method of claim 1 , wherein an elongation of the first particles is at least about 50% greater than an elongation of the second particles.

8. The method of claim 1 , wherein the metal alloy comprises a first composition, and wherein the method further comprises forming the substrate from a second composition, different from the first composition.

9. The method of claim 1 , wherein the first and second particles and the substrate are not subject to a heat treatment during the cold spraying that would further modify thermomechanical properties of the first and second particles and the substrate.

10. The method of claim 8 , wherein the second composition comprises the metal alloy that has not been subjected to a heat treatment prior to cold spraying.

11. The method of claim 1 , wherein each of the first component and the second component of the deposit is characterized by grain boundaries and dislocation networks formed at interfaces of localized deposits corresponding to deposited respective first and second particles.

12. The method of claim 1 ,
wherein the first particles comprise hardened particles subjected to a hardening heat treatment, and
wherein the second particles comprise annealed particles subjected to an annealing heat treatment.

13. The method of claim 1 , wherein the first component has a first microstructure and the second component has a second microstructure, different from the first microstructure.

14. The method of claim 1 , wherein the second particles have either been subjected to a different heat treatment than the first particles prior to cold spraying, or not been subjected to heat treatment prior to cold spraying.

15. The method of claim 1 , wherein the substrate comprises a component of a gas turbine engine.

16. The method of claim 15 , wherein the deposit comprises at least one of a barrier coating or a repair joint.

17. The method of claim 1 , wherein the first component and the second component are non-homogeneously distributed throughout the deposit in a direction between a surface of the deposit and a bulk of the deposit.

18. The method of claim 1 , wherein an average size of the first particles is different from an average size of the second particles.

Assignees

• Rolls Royce Corp
• Rolls Royce Nam Tech Inc

Inventors

• Gold Matthew R
• Loftus Peter Joseph

Classifications

• B22F1/142

  Thermal or thermo-mechanical treatment · CPC title

• C23C30/005

  on hard metal substrates · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F2304/10

  Micron size particles, i.e. above 1 micrometer up to 500 micrometer · CPC title

• B22F2303/30

  Coating alloy · CPC title