Reinforcement of a deposited metallic structure using reinforcing particles

Patent metadata

Field	Value
Publication number	US-2018178331-A1
Application number	US-201615388567-A
Country	US
Kind code	A1
Filing date	Dec 22, 2016
Priority date	Dec 22, 2016
Publication date	Jun 28, 2018
Grant date	—

Abstract

A method for forming a reinforced metallic structure includes depositing a mixture of metallic particles and reinforcing particles on a formation surface of a tool by cold-spraying the metallic particles to form a layer of mixed material, the formation surface corresponding to a desired shape of the reinforced metallic structure. The method also includes removing the layer of mixed material from the formation surface to create the reinforced metallic structure

First claim

1 . A method for forming a reinforced metallic structure, comprising:
depositing a mixture of metallic particles and reinforcing particles on a formation surface of a tool by cold-spraying the metallic particles to form a layer of mixed material, the formation surface corresponding to a desired shape of the reinforced metallic structure; and removing the layer of mixed material from the formation surface to create the reinforced metallic structure.

2 . The method of claim 1 , wherein depositing the mixture of the metallic particles and the reinforcing particles includes depositing the metallic particles using a cold-spray gun and simultaneously depositing the reinforcing particles using a second deposition source that is separate from the cold-spray gun.

3 . The method of claim 1 , wherein depositing the mixture of the metallic particles and the reinforcing particles includes combining the metallic particles and the reinforcing particles in a mixing chamber of a cold-spray gun.

4 . The method of claim 3 , wherein the metallic particles and the reinforcing particles are accelerated separately prior to being combined in the mixing chamber.

5 . The method of claim 1 , wherein depositing the mixture of the metallic particles and the reinforcing particles includes:
combining the metallic particles and the reinforcing particles into reinforced particles; and depositing the reinforced particles using a cold-spray gun.

6 . The method of claim 1 , wherein the reinforcing particles include at least one of a ceramic oxide, a boride, a carbide, a nitride, or high-strength metallic particles.

7 . The method of claim 1 , wherein the reinforced metallic structure has a greater tensile strength than a similar structure formed without reinforcing particles.

8 . A system for forming a reinforced metallic structure, comprising:
a tool having a formation surface corresponding to a desired shape of the reinforced metallic structure; a cold-spray gun configured to output a gas including metallic particles towards the formation surface at a velocity sufficiently great to cause the metallic particles to bond together; and a device capable of outputting reinforcing particles towards the formation surface at a same time that the cold-spray gun outputs the gas towards the formation surface such that a combination of the metallic particles and the reinforcing particles form the reinforced metallic structure.

9 . The system of claim 8 , further comprising a device for separating the reinforced metallic structure from the tool.

10 . The system of claim 8 , wherein the device capable of outputting the reinforcing particles includes a second deposition source that is separate from the cold-spray gun.

11 . The system of claim 8 , wherein:
the cold-spray gun includes a mixing chamber in which the reinforcing particles and the metallic particles mix such that the cold-spray gun outputs a mixture of the reinforcing particles and the metallic particles; and the device capable of outputting the reinforcing particles is the cold-spray gun.

12 . The system of claim 11 , wherein the cold-spray gun is configured to accelerate the reinforcing particles and the metallic particles separately prior to the reinforcing particles and the metallic particles reaching the mixing chamber.

13 . The system of claim 8 , wherein:
the reinforcing particles and the metallic particles are combined into reinforced particles prior to being provided to the cold-spray gun; and the device capable of outputting the reinforcing particles is the cold-spray gun.

14 . The system of claim 8 , wherein the reinforcing particles include at least one of a ceramic oxide, a boride, a carbide, a nitride, or high-strength metallic particles.

15 . The system of claim 8 , wherein the reinforced metallic structure has a greater tensile strength than a similar structure formed without reinforcing particles.

16 . A reinforced metallic structure for use in an aircraft prepared by a method comprising the steps of:
depositing a mixture of metallic particles and reinforcing particles on a formation surface of a tool by cold-spraying the metallic particles to form a layer of mixed material; and removing the layer of material from the formation surface to create the reinforced metallic structure.

17 . The reinforced metallic structure of claim 16 , wherein depositing the mixture of the metallic particles and the reinforcing particles includes depositing the metallic particles using a cold-spray gun and simultaneously depositing the reinforcing particles using a second deposition source that is separate from the cold-spray gun.

18 . The reinforced metallic structure of claim 16 , wherein depositing the mixture of the metallic particles and the reinforcing particles includes combining the metallic particles and the reinforcing particles in a mixing chamber of a cold-spray gun.

19 . The reinforced metallic structure of claim 18 , wherein the metallic particles and the reinforcing particles are accelerated separately prior to being combined in the mixing chamber.

20 . The reinforced metallic structure of claim 16 , wherein depositing the mixture of the metallic particles and the reinforcing particles includes:
combining the metallic particles and the reinforcing particles into reinforced particles; and depositing the reinforced particles using a cold-spray gun.

Assignees

• United Technologies Corp

Inventors

• Roberge Gary D
• Brindley William J

Classifications

• C23C24/04

  Impact or kinetic deposition of particles · CPC title

• F05D2230/31

  Layer deposition · CPC title

• B22F3/02

  Compacting only · CPC title

• B23P6/045 Primary

  of turbine components, e.g. moving or stationary blades, rotors, etc. · CPC title

• F05D2220/32

  in gas turbines · CPC title