Additive friction stir deposition on cold sprayed barrier layer

Patent metadata

Field	Value
Publication number	US-2024416448-A1
Application number	US-202218712425-A
Country	US
Kind code	A1
Filing date	Nov 25, 2022
Priority date	Nov 30, 2021
Publication date	Dec 19, 2024
Grant date	—

Abstract

A method of manufacturing an article is described. At S 102 , the method comprises obtaining a first layer having a first face and a reverse second face, wherein the first layer comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy. At S 104 , the method comprises providing a second layer on the first face of the first layer by cold spraying particles comprising a second metal thereupon, wherein the second metal is a second aluminium alloy. At S 106 , the method comprises depositing a third layer on the second layer by additive friction stir deposition using a third metal, wherein the third metal is a third aluminium alloy.

First claim

What is claimed is:

1 . A method of manufacturing an article, the method comprising:
obtaining a first layer having a first face and a reverse second face, wherein the first layer comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy; providing a second layer on the first face of the first layer by cold spraying particles comprising a second metal thereupon, wherein the second metal is a second aluminium alloy; and depositing a third layer on the second barrier layer by additive friction stir deposition using a third metal, wherein the third metal is a third aluminium alloy; wherein:
the second layer is a barrier layer; and
the heat treatable first aluminium alloy is heat treated in a T or a W temper designation before providing the second layer thereon.

2 . The method according to claim 1 , wherein the heat treatable first aluminium alloy is a 2XXX, a 6XXX, a 7XXX or an 8XXX series wrought aluminium alloy.

3 . The method according to claim 1 , wherein the second aluminium alloy is a non-heat treatable second aluminium alloy.

4 . The method according to claim 3 , wherein the non-heat treatable second aluminium alloy is an Al—Mg—Sc based alloy, an Al—Mg—Zr based alloy, an Al—Mg—Sc—Zr based alloy or an Al—Mg—Zr—Sc based alloy.

5 . The method according to claim 1 , wherein a thickness of the second layer is determined, at least in part, by a heat input during depositing of the third layer.

6 . The method according to claim 5 , wherein a ratio of respective thicknesses of the second layer to the third layer is in a range from 1:2 to 2:1.

7 . The method according to claim 5 , wherein the thickness of the second layer is in a range from 1 mm to 20 mm.

8 . The method according to claim 1 , wherein the cold spraying comprises cold spraying using helium.

9 . The method according to claim 1 , wherein the third aluminium alloy is a non-heat treatable third aluminium alloy.

10 . The method according to claim 9 , wherein the third aluminium alloy is an Al—Mg—Sc based alloy, an Al—Mg—Zr based alloy, an Al—Mg—Sc—Zr based alloy or an Al—Mg—Zr—Sc based alloy.

11 . The method according to claim 1 , comprising aging before and/or after providing the second layer and/or the third layer.

12 . The method according to claim 1 , wherein a ratio of respective hardnesses of the first layer before and after depositing the third layer is in a range from 1:0.75 to 1:1.25.

13 . An article comprising a cold sprayed layer Al—Mg—(Sc, Zr) based alloy applied on a heat treatable aluminium alloy as a barrier layer, wherein the barrier layer is between the heat treatable aluminium alloy and an additive friction stir deposition aluminium alloy.

Assignees

• Bae Systems Plc

Inventors

• Price Howard James

Classifications

• C23C24/04

  Impact or kinetic deposition of particles · CPC title

• C22F1/04

  of aluminium or alloys based thereon · CPC title

• B32B15/016 Primary

  all layers being formed of aluminium or aluminium alloys · CPC title

• B23K20/128

  making use of additional material · CPC title

• B23K20/122

  using a non-consumable tool, e.g. friction stir welding · CPC title