|
Pub. No. |
Filed |
Assignee/Inventors |
Title/Abstract |
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20010042508 |
May 2, 2001 |
|
ADVANCED COLD SPRAY SYSTEM |
|
DOWNLOAD |
Albert Kay |
The invention relates to an improved design for a spray gun and
application system for cold gas dynamic spraying of a metal, alloy,
polymer, or mechanical mixtures thereof. The gun includes a rear housing
removably affixed to the rear housing comprising a powder inlet and a
gas inlet, a front housing removably affixed to the rear housing and
comprising an mixing cavity therein for mixing of the powder and gas and
an exit there from, a nozzle holder having a bore disposed there through
and removably affixed to the front housing, and a nozzle positioned
within the nozzle holder, an interior taper of the nozzle holder bore
complementing an exterior taper of the nozzle, said nozzle having an
initially converging, subsequently diverging centrally disposed bore
therein adapted to receive the mixed powder and gas from the mixing
chamber. |
|
Jeganathan Karthikeyan |
|
20020033135 |
Nov. 30, 2001 |
ASB Industries |
COLD SPRAY SYSTEM NOZZLE |
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DOWNLOAD |
Albert Kay |
The invention relates to an improved design for a spray gun and
application system for cold gas dynamic spraying of a metal, alloy,
polymer, or mechanical mixtures thereof. The gun includes a rear housing
comprising a powder inlet and a gas inlet, a front housing removably
affixed to the rear housing and comprising an mixing cavity therein for
mixing of the powder and gas and an exit there from, a nozzle holder
having a bore disposed there through and removably affixed to the front
housing, and a nozzle positioned within the nozzle holder, an interior
taper of the nozzle holder bore complementing an exterior taper of the
nozzle, said nozzle having an initially converging, subsequently
diverging centrally disposed bore therein adapted to receive the mixed
powder and gas from the mixing chamber. |
|
Jeganathan Karthikeyan |
|
20060108031 |
Nov. 23, 2004 |
United Technologies Corporation |
COLD GAS DYNAMIC SPRAYING OF HIGH STRENGTH COPPER |
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DOWNLOAD |
Jeffrey D. Haynes |
A process for forming an article, such as a combustion chamber liner,
comprises the steps of providing a mandrel formed from a material, such
as an aluminum containing material, having a net shape of the article to
be made, depositing a powdered metal material onto the mandrel without
melting the powdered metal material, and removing the material forming
the mandrel to leave a free standing monolithic article. In a preferred
embodiment of the present invention, the powdered metal material
comprises powdered GRCop-84. Alternatively, the powdered metal material
may be GRCop-42. |
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20020066770 |
Dec. 5, 2000 |
Siemens Westinghouse Power Corporation |
COLD SPRAY REPAIR PROCESS |
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DOWNLOAD |
Gregg P. Wagner |
A process (30) for the repair of a component part (36, 66) incorporating
a cold spray process step (50) for depositing material particles (54) to
fill a discontinuity (40) in the part surface (42) or to create a
desired surface geometry (78) on the part (66). The cold spray process
may be controlled to provide a grit blasting effect prior to depositing
the material in order to remove contaminants (48) from the surface of
the part. The material deposited (56) by the cold spray process may form
a joint (78) between an insert (72) and the part (66). The process may
be used to repair parts made of directionally solidified (DS) or single
crystal (SC) base material (44) without causing a re-crystallization of
the base material. The process may further be used to deposit repair
material (56) over a braze material (22). |
|
Brij B. Seth |
|
Allister William James |
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20020071906 |
Dec. 13, 2000 |
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METHOD AND DEVICE FOR APPLYING A COATING |
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DOWNLOAD |
William P. Rusch |
An apparatus and method for applying a coating to an article uses a
nozzle having a converging portion and a diverging portion downstream
thereof forming a throat therebetween. A gas inlet is upstream of the
converging portion of the nozzle for receiving a supply of high pressure
gas and a powder inlet introduces a powdered feed material into a gas
stream in the nozzle downstream of the throat. A gas heater heats the
gas stream from the gas inlet upstream of the converging portion. |
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20020073982 |
Dec. 16,2000 |
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GAS-DYNAMIC COLD SPRAY LINING FOR ALUMINUM ENGINE BLOCK CYLINDERS |
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DOWNLOAD |
Howard Douglas Blair |
A method and apparatus for gas-dynamic cold spraying a liner 3 in a
cylinder 2 of an aluminum engine block 1 is provided. The gas-dynamic
cold spray liner 3 allows the aluminum engine block 1 to have a hardened
cylinder surface 10 without the induction of residual hoop stress within
the aluminum engine block 1. |
|
Rodney John Tabaczynski |
|
Tsung-Yu Pan |
|
Furqan Zafar Shaikh |
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20020105358 |
Jan. 17,2002 |
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METHOD AND APPARATUS FOR FORMING ELECTRIC CIRCUIT |
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DOWNLOAD |
Kinya Horibe |
The apparatus forms an electric circuit on a construction member of a
machine based on a set of three-dimensional data. The data defines a
position and a profile of the construction member, a position of the
electric circuit, and a shape of the electric circuit. The electric
circuit is used for electrical connection between electric instruments
mounted on the machine. The data is associated with a reference
coordinate system provided in the machine, and the data includes
coordinates of points for determining arrangement of the electric
circuit, a distance between any two of the points adjacent to each
other, and a cross-sectional area of the electric circuit associated
extended between the two points. The apparatus has a storage means for
storing the data, a jet means for jetting a molten metal, a first
transfer means for moving the construction member relative to the jet
means, and a control means for jetting the molten metal against the
construction member to deposit the molten metal and for controlling the
relative movement between the construction member and the jet means
based on the data. The jet means can jet the molten metal against the
construction member so that the molten metal can be deposited on a
surface of the construction member to form the electric circuit on the
construction member. |
|
Hitoshi Ushijima |
|
Tatsuya Kato |
|
Hitoshi Ohashi |
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20020182313 |
Jul. 29, 2002 |
Ford Motor Company |
METHOD OF MANUFACTURING A PERMANENT MAGNET USING KINETIC SPRAY |
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DOWNLOAD |
John Matthew Ginder |
Amethod of manufacturing a permanent magnet by the steps of preparing an
admixture of magnetic material and binder material, the admixture
material having a particle size of less
than 325 mesh. Then heating a carrier gas to a temperature substantially
below the melting point of either component of the admixture. The
admixture is introduced into the carrier gas and the admixture is
sprayed atop a ductile carrier. The admixture adheres to the carrier and
forms a solid permanent magnet. An electric field is applied to the
sprayed admixture to create a permanent magnetic moment. |
|
Robert Corbly McCune |
|
Franco Leonardi |
|
20020182314 |
Jul. 29, 2002 |
Ford Motor Company |
METHOD OF MANUFACTURING ELECTRIC MACHINES USING KINETIC SPRAY |
|
DOWNLOAD |
John Matthew Ginder |
A method of manufacturing electric machines comprising the steps of
kinetically spraying a powdered admixture of magnetic material and
ductile binder material on to a substrate and applying a concentrated
magnetic field to the sprayed admixture to cause magnetic dipole
alignment in the sprayed admixture. The magnets of the present invention
may be integrally formed atop carriers to form electrical machines such
as motors, generators, alternators, solenoids, and actuators. The
manufacturing techniques used in this invention may produce highly
defined articles that do not require additional shaping or attaching
steps. Very highpurity permanent and soft magnetic materials, and
conductors with low oxidation are produced. |
|
Robert Corbly McCune |
|
Franco Leonardie |
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20020182411 |
Jul. 29, 2002 |
Ford Motor Company |
ELECTROMAGNETIC DEVICE |
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DOWNLOAD |
Thomas Hubert Van Steenkiste |
An electric machine made from kinetically sprayed permanent magnet
material and a binder material form a composite admixture having
microstructure of permanent magnet material embedded in the binder
material. The admixture has a permanent magnetic moment. The magnets of
the present invention may be integrally formed atop carriers to form
electrical machines such as motors, generators, alternators, solenoids,
and actuators. The manufacturing techniques used in this invention may
produce highly defined articles that do not require additional shaping
or attaching steps. Very high-purity permanent and soft magnetic
materials, and conductors with low oxidation are produced. |
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20020192479 |
Apr. 1,2002 |
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METHOD OF PRODUCING NANOCOMPOSITE COATINGS |
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DOWNLOAD |
Ramasis Goswami |
A method of producing a nanocomposite coating without gaseous precursor
reactants. A non-nanocrystalline particulate containing a polymorphic
material in an atmospheric phase is introduced into a high-velocity gas
jet. The projected particulate is allowed to impact a substrate at a
velocity effective to cause at a least a portion of the polymorphic
material to transform to a nanocrystalline, high pressure phase. |
|
Sanjay Sampath |
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John Parise |
|
Herbert Herman |
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20030017358 |
Mar. 19, 2001 |
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METAL-ZIRCONIA COMPOSITE COATING WITH RESISTANCE TO MOLTEN METALS AND
HIGH TEMPERATURE CORROSIVE GASES |
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DOWNLOAD |
Harold Haruhisa Fukubayashi |
The coated device contains a coating for use with corrosive environments
at high temperatures. The device has a bond coat consisting essentially
of, by weight percent, 0 to 5 carbon, 20 to 40 chromium, 0 to 5 nickel,
0 to 5 iron, 2 to 25 total molybdenum plus tungsten, 0 to 3 silicon 0 to
3 boron and balance cobalt and essential impurities to provide
sulfidation resistance at high temperatures. A zirconia-base ceramic
coating covers the bond coat for heat resistance. Optionally, a boride
or carbide coating covers the zirconia for additional resistance to
erosion. |
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20030039856 |
Aug. 15,2001 |
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PRODUCT AND METHOD OF BRAZING USING KINETIC SPRAYED COATINGS |
|
DOWNLOAD |
Zhibo Zhao |
The present invention is directed to a process for preparing aluminum
and aluminum alloy surfaces in heat exchangers for brazing by depositing
thereon a kinetic sprayed brazing composition. The process
simultaneously deposits monolith or composite coatings that can include
all braze materials and corrosion protection materials used in the
brazing of aluminum fins to plates and tubes in a single stage. |
|
John Robert |
|
Thomas Hubert Van Steenkiste |
|
Yang Luo |
|
Hartley F. Hutchins |
|
Bryan A. Gillispie |
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20030077952 |
Oct. 9, 2001 |
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KINETIC SPRAYED ELECTRICAL CONTACTS ON CONDUCTIVE SUBSTRATES |
|
DOWNLOAD |
George Albert Drew |
The present invention is directed to electrical contacts that comprise
spaced electrically conductive particles embedded and bonded into the
surface of conductors in which the particles have been kinetically
sprayed onto the conductors with sufficient energy to form direct
mechanical bonds between the particles and the conductors in a
pre-selected location and particle number density that promotes high
surface-to-surface contact and reduced contact resistance between the
conductors. |
|
Daniel William Gorkiewicz |
|
Bryan A. Gillispie |
|
Thomas Hubert Van Steenkiste |
|
20030175559 |
Mar. 15,2002 |
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KINETICALLY SPRAYED ALUMINUM METAL MATRIX COMPOSITES FOR THERMAL
MANAGEMENT |
|
DOWNLOAD |
Alaa A. Elmoursi |
Disclosed is a method for forming a heat sink laminate and a heat sink
laminate formed by the method. In the method a particle mixture is
formed from a metal, an alloy or mixtures thereof with a ceramic or
mixture of ceramics. The mixture is kinetically sprayed onto a first
side of a dielectric material to form a metal matrix composite layer.
The second side of the dielectric material is thermally coupled to a
heat sink baseplate, thereby forming the heat sink laminate. |
|
Thomas H. Van Steenkiste |
|
Brian K. Fuller |
|
Brvan A. Gillispie |
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Donald T. Morelli |
|
Daniel W. Gorkiewicz |
|
20030184976 |
Apr. 2,2002 |
|
ELECTROMAGNETIC INTERFERENCE SHIELD FOR OVERMOLDED PACKAGING OF AN
ELECTRONIC ASSEMBLY |
|
DOWNLOAD |
Bruce A. Myers |
An overmolded electronic assembly having an electromagnetic interference
shield, in the form of a thin metal film or foil, coupled to the top of
or within an overmolded body. The shield effectively reduces the amount
of electromagnetic interference ("EMI") emissions from penetrating
within the assembly to the circuit board without substantially
increasing the cost of the unit. Thus, an electronic assembly having
improved vibration, moisture, and EM1 emission resistance is achieved as
compared with traditional overmolded or metal assemblies. Further,
because the shield can be formed on the electronic assembly in one
continuous processing step, a substantial savings in time and cost for
the manufacturing process is also realized. |
|
Jeenhuei S. Tsai |
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Suresh K. Chengalva |
|
Scott D. Brandenburg |
|
20030190413 |
Apr. 5,2002 |
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METHOD OF MAINTAINING A NON-OBSTRUCTED INTERIOR OPENING IN KINETIC SPRAY
NOZZLES |
|
DOWNLOAD |
John R. Smith |
A method of maintaining a non-obstructed interior opening in a kinetic
spray nozzle is disclosed. The method includes the steps of providing a
mixture of particles including first particle population and a second
particle population; entraining the mixture of particles into a flow of
a gas at a temperature below the melt temperature of the particle
populations; and directing the mixture of particles entrained in the
flow of gas through a supersonic nozzle to accelerate the first particle
population to a velocity sufficient to result in adherence of the first
particle population on a substrate positioned opposite the nozzle. The
operating conditions of the kinetic spray system are selected such that
the second particle pop~lathn-inso t accelerated to a velocity
sufficient to result in adherence when it impacts the substrate. The
inclusion of the second particle population maintains the supersonic
nozzle in a non-obstructed condition and also enables one to raise the
main gas operating temperature to a much higher level, thereby
increasing the deposition efficiency of the first particle population. |
|
Daniel William Gorkiewicz |
|
Alaa A. Elmoursi |
|
Bryan A. Gillispie |
|
Nilesh B. Patel |
|
Thomas Hubert Van Steenkiste |
|
20030190414 |
Apr. 5,2002 |
|
LOW PRESSURE POWDER INJECTION METHOD AND SYSTEM FOR A KINETIC SPRAY
PROCESS |
|
DOWNLOAD |
Thomas Hubert Van Steenkiste |
Disclosed is a method and a nozzle for a kinetic spray system that uses
much lower powder pressures than previously used in kinetic spray
systems. The method permits one to significantly decrease the cost of
the powder delivery portion of the system, to run the system at higher
temperatures for increased deposition efficiency and to eliminate
clogging of the nozzle. The nozzle is a supersonic nozzle having a
throat located between a converging region and a diverging region, with
the diverging region defined between the throat and an exit end. At
least one injector is positioned between the throat and the exit end
with the injector in direct communication with the diverging region. The
powder particles to be sprayed are injected through the at least one
injector and entrained in a gas flowing through the nozzle. The
entrained particles are accelerated to a velocity sufficient to cause
them to adhere to a substrate positioned opposite the nozzle. |
|
20030190415 |
Apr. 5,2002 |
|
METHOD OF PRODUCING A COATING USING A KINETIC SPRAY PROCESS WITH LARGE
PARTICLES AND NOZZLES FOR THE SAME |
|
DOWNLOAD |
Thomas Hubert Van Steenkiste |
A method of depositing large particles having an average nominal
diameter of up to 250 microns onto substrates using a kinetic spray
system is disclosed. The method utilizes a powder injector tube having a
reduced inner diameter and a de Lava1 type nozzle having an elongated
throat to exit end length. The method permits deposition of much larger
particles than previously possible. |
|
20030207148 |
Apr. 16, 2003 |
Delphi Technolohies, Inc. |
PRODUCT AND METHOD OF BRAZING USING KINETIC SPRAYED COATINGS |
|
DOWNLOAD |
Bryan A. Gillispie |
The present invention is directed to a process for preparing aluminum
and aluminum alloy surfaces in heat exchangers for brazing by depositing
thereon a kinetic sprayed brazing composition. The process
simultaneously deposits monolith or composite coatings that can include
all braze materials and corrosion protection materials used in the
brazing of aluminum fins to plates and tubes in a single stage. |
|
Zhibo Zhao |
|
John Robert Smith |
|
Thomas Hubert Van Steenkiste |
|
Alaa A. Elmoursi |
|
Yang Luo |
|
Hartley F. Hutchins |
|
20030209286 |
Jun. 17,2003 |
Ford Motor Company |
METHOD OF MANUFACTURING ELECTROMAGNETIC DEVICES USING KINETIC SPRAY |
|
DOWNLOAD |
Franco Leonardi |
A method of manufacturing electric machines comprised of geometrically
patterned arrays of permanent magnets, soft magnetic materials, and
electrical conductors deposited by kinetic spraying methods directly
atop a carrier. The magnets and planar coils of the present invention
may be integrally formed atop carriers to form electrical machines such
as motors, generators, alternators, solenoids, and actuators. The
manufacturing techniques used in this invention may produce highly
defined articles that do not require additional shaping or attaching
steps. Very high-purity permanent and soft magnetic materials, and
conductors with low oxidation are produced. |
|
John Matthew Ginder |
|
Robert Corbly McCune |
|
20030219542 |
May 21,2003 |
|
METHOD OF FORMING DENSE COATINGS BY POWDER SPRAYING |
|
DOWNLOAD |
Frank J. Ewasyshyn |
A dense coating deposition process by powder spraying is disclosed. A
compressed gas is expanded through a supersonic nozzle and powder
containing a mixture of at least one material selected from the group
consisting of metals and metal alloys and at least one ceramic material
is introduced into the gas flow slightly downstream of the throat of the
nozzle. The coating is formed by the powder impacting and
metallurgically bonding to the substrate and can be applied in multiple
layers. The coating can suffice as a finished surface, corrosion
protectant, leak sealer, and material build up application. |
|
Alexandre I. Kachirine |
|
Alexander V. Shkidkin |
|
Oleg E. Kliouev |
|
Timour V. Bouzdygar |
|
Roman Gr. Maev |
|
John M. Paille |
|
Emil E. Strumban |
|
20030219576 |
May 23,2002 |
|
COPPER CIRCUIT FORMED BY KINETIC SPRAY |
|
DOWNLOAD |
Alaa A. Elmoursi |
The invention concerns a copper-based circuit having an electrically
insulative substrate, a bond layer including silver formed over select
portions of the substrate according to a desired shape of the circuit,
and an electrically conductive layer including plastically deformed
particles of copper deposited on the bond layer. Furthermore, the
invention also concerns a process for forming a copper-based circuit,
wherein the process includes the steps of providing an electrically
insulative substrate, forming a bond layer including silver over select
portions of the substrate according to a desired shape of the circuit,
and depositing copper on the bond layer by the steps of introducing
copper particles into a pressurized carrier gas, forming the pressurized
carrier gas and the copper particles into a supersonic jet, and
directing the jet toward the bond layer formed over the substrate such
that the jet has a velocity suEcient to cause plastic deformation of the
copper particles onto the bond layer, thereby forming an electrically
conductive layer on the bond layer. |
|
Frans P. Lautzenhiser |
|
Albert B. Campbell |
|
John R. Smith |
|
20040016793 |
Jul. 24, 2002 |
|
METHOD FOR DIRECT APPLICATION OF FLUX TO A BRAZING SURFACE |
|
DOWNLOAD |
Zhibo Zhao |
A method is disclosed for direct application of a brazing flux material
to a brazing surface. The method includes the step of applying a brazing
filler material to a substrate utilizing a kinetic spray process to form
a brazing surface. Following application of the brazing filler material
to the substrate brazing flux material can be directly applied to the
brazing surface as either a dry powder or a wet slurry. The nature of
the brazing surface allows the applied flux material to adhere to the
surface without the utilization of additional binders or resin
materials. |
|
Bryan A. Gillispie |
|
John R. Smith |
|
Thomas Hubert Van Steenkiste |
|
Yang Luo |
|
20040026030 |
Oct. 23, 2001 |
|
COMPOSITE STRUCTURE BODY AND METHOD AND APPARATUS FOR MANUFACTURING
THEREOF |
|
DOWNLOAD |
Hironori Hatono |
A structure body having the constitution in which the crystals of more
than one types of brittle materials such as ceramics, metalloids, and
the like are dispersed, the portion composed of the brittle materials is
polycrystalline, the crystals constituting the polycrystalline portion
substantially lacks the crystalline orientation, and the boundary layers
composed of glassy substances are substantially absent in the boundary
face between the crystals. Accordingly, it is possible to obtain a
structure body composed of more than one types of brittle materials and
having novel properties without involving a heatingkintering process. |
|
Masakatsu Kiyohara |
|
Katsuhiko Mori |
|
Tatsuro Yokoyama |
|
Atsushi Yoshida |
|
Tomokazu Ito |
|
Jun Akedo |
|
20040037954 |
Jun. 4,2003 |
Linde Aktiengesellschaft |
PROCESS AND DEVICE FOR COLD GAS SPRAYING |
|
DOWNLOAD |
Peter Heinrich |
According to the invention, the cold gas spraying process is carried out
in a vacuum chamber at a pressure that is below 800 mbar (80 kPa). To do
this, the cold gas spray gun (3) and the work piece (5) are located in a
vacuum chamber (4). This enables use of optimally acting carrier gases
such as, for example, helium or helium-containing mixtures. |
|
Heinrich Kreye |
|
Erich Muehlberger |
|
20040058064 |
Apr. 17,2003 |
Delphi Technolohies, Inc. |
SPRAY SYSTEM WITH COMBINED KINETIC SPRAY AND THERMAL SPRAY ABILITY |
|
DOWNLOAD |
Brian K. Fuller |
Disclosed is a system and a method for applying both a kinetic spray
applied coating layer and a thermal spray applied layer onto a substrate
using a single application nozzle. The system includes a higher heat
capacity gas heater to permit oscillation between a kinetic spray mode
wherein the particles being applied are not thermally softened and a
thermal spray mode wherein the particles being applied are thermally
softened prior to application. The system increases the versatility of
the spray nozzle and addresses several problems inherent in kinetic
spray applied coatings. |
|
Thomas Hubert Van Steenkiste |
|
20040058065 |
Jul. 9, 2003 |
|
SPRAY SYSTEM WITH COMBINED KINETIC SPRAY AND THERMAL SPRAY ABILITY |
|
DOWNLOAD |
Thomas Hubert Van Steenkiste |
Disclosed is a system and a method for simultaneously applying a kinetic
spray coating and a thermal spray coating onto a substrate using a
single application nozzle to produce a combined coating. The system may
include a higher heat capacity gas heater to permit both the thermal
spray and the kinetic spray. The method involves providing two
populations of particles to the nozzle simultaneously wherein one
population is thermally softened in the nozzle under the spray
parameters and the other is not. The system increases the versatility of
the spray nozzle and addresses several problems inherent in kinetic
spray applied coatings. |
|
Brian K. Fuller |
|
20040065432 |
Oct. 2, 2002 |
|
HIGH PERFORMANCE THERMAL STACK FOR ELECTRICAL COMPONENTS |
|
DOWNLOAD |
John R. Smith |
A thermal stack laminate and a process for producing the same are
disclosed. The thermal stack laminate includes a baseplate formed from a
heat sink material that has on a first surface a very thin thermally
sprayed alumina layer to serve as a dielectric and attached to the
alumina is a kinetic spray applied solderablc layer. An electrical
component is attached to the thermal stack laminate by solder. The
thermal stack laminate optionally includes a kinetic spray applied first
and/or second metal matrix composite layer between the baseplate and the
alumina layer and between the alumina layer and the solderable material.
In addition, one other optional layer comprises a first layer of the
solderable material applied via a thermal spray process followed by the
remainder of the solderable material applied by a kinetic spray process. |
|
Alaa A. Elmoursi |
|
Xiao-Gang Wang |
|
Gary L. Eesley |
|
Nilesh B. Patel |
|
Bruce A. Myers |
|
20040072008 |
Oct. 1, 2003 |
Delphi Technolohies, Inc. |
KINETIC SPRAYED ELECTRICAL CONTACTS ON CONDUCTIVE SUBSTRATES |
|
DOWNLOAD |
Thomas Hubert Van Steenkiste |
The present invention is directed to electrical contacts that comprise
spaced electrically conductive particles embedded and bonded into the
surface of conductors in which the particles have been kinetically
sprayed onto the conductors with sufficient energy to form direct
mechanical bonds between the particles and the conductors in a
pre-selected location and particle number density that promotes high
surface-to-surface contact and reduced contact resistance between the
conductors. |
|
George Albert Drew |
|
Daniel William Gorkiewicz |
|
Bryan A. Gillispie |
|
20040076807 |
Oct. 21, 2002 |
Ford Motor Company |
METHOD OF SPRAY JOINING ARTICLES |
|
DOWNLOAD |
Grigoriy Grinberg |
The present invention relates to a method of providing a spray formed
composite article. The method comprises providing a first article. The
first article is a spray formed article. A second article is located
adjacent the first article. Metallic particles are sprayed onto the
articles and allowed to form a metal deposit that extends between and
connects the first and second articles. |
|
Matthew M. Shade |
|
David Robert Collins |
|
20040101620 |
Nov. 22,2002 |
|
METHOD FOR ALUMINUM METALIZATION OF CERAMICS FOR POWER ELECTRONICS
APPLICATIONS |
|
DOWNLOAD |
Alaa A. Elmoursi |
A method is disclosed for the aluminum metalization of ceramics using a
kinetic spray system. The method is rapid, does not require any surface
preparation of the ceramicnsubstrate, and produces a coating having
properties similar to bulk aluminum. The method permits aluminum
coatings of from microns to centimeters in thickness. The method further
more enables one to quickly apply copper or copper alloys to the
aluminum metalization to provide for soldering pads to attach other
components. The method finds special application in the area of high
powered electronics. |
|
Donald T. Morelli |
|
Nilesh B. Patel |
|
20040110021 |
Aug. 1, 2002 |
Siemens Westinghouse Power Corporation |
WEAR AND EROSION RESISTANT ALLOYS APPLIED BY COLD SPRAY TECHNIQUE |
|
DOWNLOAD |
Brij B. Seth |
Awear alloy coating (14) applied to a substrate material (12) by a cold
spray process. Particles of the wear alloy coating material (16) are
directed toward a target surface (18) of the substrate at a velocity
suficiently high for the particles to deform and to adhere to the target
surface. The size and composition of the particles may be varied during
the cold spray process to produce a coating with a varying property
across the depth of the coating. Particles of the wear alloy material
may be applied by cold spraying along with particles of a second
material such as a lubricant or a ceramic material. For Group 5 hard
facing materials, the size and distribution of the embedded carbide
nodules may be controlled by controlling the selection of the carbide
particles being sprayed. The cold spray process permits a wear alloy
coating to be applied proximate a brazed joint or over a directionally
stabilized or single crystal material without degrading the underlying
material. |
|
Gregg P. Wagne |
|
20040126499 |
Jun. 4, 2003 |
Linde Aktiengesellschaft |
PROCESS AND DEVICE FOR COLD GAS SPRAYING |
|
DOWNLOAD |
Peter Heinrich |
According to the invention, the carrier gas that accelerates the spray
particles during cold gas spraying, or a component of the carrier gas,
is captured, cleaned and collected after the cold gas spraying process.
The cold gas spray gun (3) and the work piece (5) are located in a
closed tank (4) from which the used carrier gas is removed, a~lda
dvalltageously the helium is recovered in a helium recovery unit (9).
The invention enables use of optimally acting carrier gases, such as,
for example, helium or helium-containing mixtures. |
|
Heinrich Kreye |
|
Werner Krommer |
|
20040142109 |
Sep. 25,2003 |
|
COATED VEHICLE WHEEL AND METHOD |
|
DOWNLOAD |
Roger W. Kaufold |
A method of coating a vehicle wheel to increase wear and corrosion
resistance of the vehicle wheel, includes the steps of providing a
vehicle wheel and applying a wear and corrosion resistant coating onto a
surface of the vehicle wheel. Thc coating is applied to at least a tire
bead retaining flange of the vehicle wheel. The coating is of particular
use with vehicle wheels made of forged aluminum. The coating is selected
from tungsten carbide, optionally including cobalt or chrome, a
nickel-based superalloy, aluminum and silicon carbide, or stainless
steel. The coating is typically applied to a thickness of about
0.004-0.01 inch. The surface of the vehicle wheel may be prepared by
mechanically abrading the surface or chemically etching the surface of
the vehicle wheel. The coating may be applied by cold spraying, thermal
spraying, or triboelectric discharge kinetic spraying and other similar
processes. |
|
Neville C. Whittle |
|
Edward P. Patrick |
|
A. Victor Pajerski |
|
20040142198 |
Jan. 21,2003 |
|
MAGNETOSTRICTIVE/MAGNETIC MATERIAL FOR USE IN TORQUE SENSORS |
|
DOWNLOAD |
Thomas Hubert Van Steenkiste |
A kinetically sprayed magnetostrictivelmagnetic material, comprising:
magnetostriction particles; magnetic particles with coercivity; a
ductile matrix for bonding the magnetostriction particles and magnetic
particles with coercivity together; wherein an applied magnetic field
will align the magnetic particles with coercivity and subsequently the
magnetostriction particles such that the magnetostrictive material will
produce a detectable change in the magnetostrictivelmagnetic material
when placed under an applied stress. A method of forming a composite
coating of magnetostrictivelmagnetic material on a substrate,
comprising: spraying a powder mixture of magnetostriction particles,
magnetic particles with coercivity and a ductile matrix in a spray gas
stream flowing at supersonic velocity against the substrate to form a
composite coating wherein an applied magnetic field will align the
magnetic particles with coercivity and subsequently the magnetostriction
particles such that the magnetostrictive material will produce a
detectable change in the magnetostrictivelmagnetic material when placed
under an applied stress. |
|
20040146640 |
Jan. 23,2003 |
|
FABRICATION AND UTILIZATION OF METALLIC POWDER PREPARED WITHOUT MELTING |
|
DOWNLOAD |
Eric Allen Ott |
A metallic alloy made of metallic constituent elements is fabricated and
utilized by first furnishing a mixture of nonmetallic precursor
compounds of the metallic constituent elements, and thereafter
chemically reducing the mixture of nonmetallic precursor compounds to
produce a metallic alloy as a metallic alloy powder, without melting the
metallic alloy. The metallic alloy powder is applied to a surface of a
substrate article, preferably in a coating, joining, or deposition
application. |
|
Andrew Philip Woodfield |
|
Cliford Earl Shamblen |
|
20040157000 |
Feb. 7,2003 |
|
METHOD FOR PRODUCING ELECTRICAL CONTACTS USING SELECTIVE MELTING AND A
LOW PRESSURE KINETIC SPRAY PROCESS |
|
DOWNLOAD |
Thomas Hubert Van Steenkiste |
A new kinetic spray process is disclosed that enables the coating to
withstand severe bending and stress without delamination. The method
includes use of a low pressure kinetic spray supersonic nozzle having a
throat located between a converging region and a diverging region. Amain
gas temperature is raised to from 1000 to 1300 degrees Fahrenheit and
the coating particles are directly injected into the diverging region of
the nozzle at a point after the throat. The particles are entrained in
the flow of the gas and accelerated to a velocity suficient to result in
partial melting of the particles upon impact on a substrate positioned
opposite the nozzle and adherence of the particles to the substrate. The
coating also has a desirable shinny surface. The method finds special
application in coating substrates for use in formation of electrical
connections. |
|
Daniel William Gorkiewicz |
|
George Albert Drew |
|
20040161530 |
Feb. 16, 2003 |
|
HERMETICALLY SEALED MICRO-DEVICE PACKAGE USTNG COLD-GAS DYNAMIC SPRAY
MATERIAL DEPOSITION |
|
DOWNLOAD |
David H. Stark |
A cover assembly for welding to a package base to form a hermetically
sealed micro-device package. The coverassembly includes a sheet of a
transparent material having a window portion. A built-up metallic frame
adheres to the sheet and circumscribes the window portion, the frame
having been deposited as follows: First, powdered metal particles are
sprayed onto a prepared area of the sheet using a gas jet at a
temperature below the fusing temperature of the particles, the jet
having a velocity sufficient to cause the particles to merge with one
another upon impact with the sheet and with one another to form an
initial continuous metallic coating adhering to the prepared area of the
sheet. Next, successive metal particles are applied over the initial
coating using the jet to form the frame incorporating the initial
continuous metallic coating as its base and having an predetermined
overall thickness. |
|
20040188124 |
Jan. 27,2004 |
|
HERMETIC WINDOW ASSEMBLIES AND FRAMES |
|
DOWNLOAD |
David H. Stark |
A frame assembly for hermetic attachment to one side of a sheet of
transparent material having a plurality of window aperture areas defined
thereon, each window aperture area being circumscribed by a frame
attachment area having a predefined plan. The frame assembly comprises a
plurality of continuous sidewalls circumscribing a plurality of frame
apertures such that some sidewalls are disposed between two adjacent
frame apertures. The sidewalls have an upper side plan configured to
substantially correspond with the predefined plans of the frame
attachment areas of the sheet. The sidewalls disposed between the
adjacent frame apertures include two generally parallel sidewall members
having an overall vertical thickness and a first connecting tab
extending there between. When viewed in cross-section taken
perpendicular to the plan view, the configuration of the sidewalls
disposed between adjacent frame apertures is characterized by the first
connecting tab having a relatively constant vertical thickness that is
significantly smaller than the overall vertical thickness of the
adjacent sidewall members. |
|
20040191543 |
Mar. 25,2003 |
Ford Motor Company |
METHOD FOR ENHANCING ADHESION OF METAL PARTICLES TO CERAMIC MODEL |
|
DOWNLOAD |
Allen Dennis Roche |
One method of the present invention relates to a method for enhancing
adhesion of sprayed metal to a ceramic model. The method is comprised of
providing the ceramic model having a spray surface, and modifying at
least a portion the spray surface of the ceramic model to enhance
adhesion of spray metal to the spray surface. |
|
John Michael Nicholson |
|
Richard L. Allor |
|
David Warren Worthey |
|
20040196028 |
Apr. 2,2003 |
|
PRINTED HIGH STRENGTH PERMANENT MAGNET TARGETS FOR MAGNETIC SENSORS |
|
DOWNLOAD |
Thaddeus Schroeder |
A process for forming magnetic target tracks for position and speed
sensors. The tracks are formed from a paste comprising a magnetic powder
material and a hardenable carrier. The tracks can be formed within
trenches in a substrate or on the substrate surface. |
|
Shih-Chia Chang |
|
Lorenzo Guadalupe Rodriguez |
|
20040197593 |
Apr. 4,2003 |
|
SURFACE MODIFICATION OF POROUS METAL SUBSTRATES USING COLD SPRAY |
|
DOWNLOAD |
Anand Chellappa |
A method of preparing the surface of a porous metal substrate to receive
a membrane. The method does not substantially decrease the average bulk
porosity of the metal substrate. A hydrogen separation membrane
supported on the porous metal substrate. A cold spray is used to reduce
surface variance. Exposure to an ion beam may also be used after
application on the cold spray to prepare the surface of the substrate
for membrane deposition. |
|
20040202797 |
Feb. 6,2004 |
Ford Global Technologies, LLC |
METHOD OF MANUFACTURING ELECTROMAGNETIC DEVICES USING KINETIC SPRAY |
|
DOWNLOAD |
John Ginder |
A method of manufacturing electric machines comprised of geometrically
patterned arrays of permanent magnets, soft magnetic materials, and
electrical conductors deposited by kinetic spraying methods directly
atop a carrier. The magnets and planar coils of the present invention
may be integrally formed atop carriers to form electrical machines such
as motors, generators, alternators, solenoids, and actuators. The
manufacturing techniques used in this invention may produce highly
defined articles that do not require additional shaping or attaching
steps. Very high-purity permanent and soft magnetic materials, and
conductors with low oxidation are produced. |
|
Robert McCune |
|
Franco Leonardi |
|
20040202885 |
Apr. 30, 2004 |
|
COMPONENT HAVING WEAR COATING APPLIED BY COLD SPRAY PROCESS |
|
DOWNLOAD |
Brij B. Seth |
A component (10) including a substrate material (12) and wear alloy
coating (14) applied to the substrate by a cold spray process. Particles
of the wear alloy coating material (16) are directed toward a target
surface (18) of the substrate at a velocity sufficiently high for the
particles to deform and to adhere to the target surface. The size andlor
composition of the particles may be varied during the cold spray process
to produce a coating with a varying property across the depth of the
coating. Particles of the wear alloy material may be applied by cold
spraying along with particles of a second material such as a lubricant
or a ceramic material. For Group 5 hard facing materials, the size and
distribution of the embedded carbide nodules may be controlled by
controlling the selection of the carbide particles being sprayed. The
cold spray process permits a wear alloy coating to be applied proximate
a brazed joint or over a directionally stabilized single crystal
material without degrading the underlying material. |
|
Gregg P. Wagner |
|
20040202886 |
Sep. 23, 2002 |
Siemens Westinghouse Power Corporation |
METHOD AND APPARATUS FOR INSTRUMENTING A GAS TURBINE COMPONENT HAVING A
BARRIER COATING |
|
DOWNLOAD |
Ramesh Subramanian |
A method (50) of instrumenting a component (10) having a barrier coating
(14). A sensor (76) is embedded within or below the coating. Material
forming the sensor is deposited within a trench (80) formed into the
barrier coating. The trench is then backfilled with material (70) to
protect the sensor from the environment within which the component is
operating. In this manner, the sensor may be embedded at any desired
location and any desired depth within a barrier coating on a previously
fabricated component. An array of sensors (98,100,102) may be embedded
across the depth of the coating to provide signals indicative of
operating conditions across the coating. The signals may be, conducted
to a connection location (24) by conductors (62, 64) that are deposited
within the trench. The trench may be formed with a laser engraving
process (54) and the material for the sensor and conductors may be
deposited with a selective laser melting process (58). |
|
20040216609 |
Jul. 31, 2002 |
|
CONTROL SYSTEM FOR HELIUM RECOVERY |
|
DOWNLOAD |
Mohamed Safdar Allie Baksh |
The invention comprises a gas recycling system comprising: a) a source
of gas having a predetermined purity (28); b) an application system (6)
that uses said gas and adds contaminants to said gas; c) an adsorption
system (1) for removing said contaminants from said gas to produce a
purified gas, and a waste gas; d) a gas purity analyzer (100) for
measuring the amount of said contaminants in said waste gas; e) conduits
((5), (a), (9) (13) and (15) connecting the gas source (4) to said
application system, said application system (6) to said adsorption
system. |
|
Scot Eric Jaynes |
|
Bernard Thomas Neu |
|
James Smolarek |
|
Mark Thomas Emley |
|
20040237789 |
Jul. 31, 2002 |
|
HELIUM RECOVERY |
|
DOWNLOAD |
Mohamed Safdar Allie Baksh |
A gas recovery system comprising a source of gas having a preselected
concentration of a desired component (9), at least one application (1)
that adds impurities to said gas, and at least one an adsorption system
(6) that purifies said gas to produce a purified gas for re-use in
application (I), wherein said at least one adsorption system includes at
least one adsorbent bed (A) having at least three layers of adsorbents.
A recovery process is also disclosed. |
|
Scot Eric Jaynes |
|
Bernard Thomas Neu |
|
James Smolarek |
|
Mark Thomas Emley |
|
20040245354 |
Jun. 4, 2003 |
Siemens Westinghouse Power Corporation |
METHOD FOR CONTROLLING A SPRAY PROCESS |
|
DOWNLOAD |
Vasudevan Srinivasan |
A method is provided for controlling a spray process that may include
measuring a particle property associated with a spray jet of particles,
calculating a centroid for the measured particle property and using the
calculated centroid as a control parameter for controlling the spray
process. At least one operating parameter associated with the spray
process may be adjusted in response to the calculated centroid to change
a trajectory of at least a portion of the particles within the spray jet
of particles. The operating parameter may be adjusted so that an
ensemble of particles having the highest measured temperature and an
ensemble of particles having the highest measured velocity and an
ensemble of particles having the highest measured flow rate are moved
more closely together to create a common region proximate a surface of a
substrate to be coated by the spray process. This may be done manually
prior to a coating run or continuously during a run using a closed-loop
feedback circuit (43) in a computer-controlled (38) spray system. |
|
20040247793 |
Jun. 9, 2003 |
Siemens Westinghouse Power Corporation |
METHOD FOR APPLYING A COATING TO A SUBSTRATE |
|
DOWNLOAD |
Andrew Jeremiah Burns |
A exemplary method of depositing a coating on a substrate using a spray
process is provided that may include selecting a desired dominant
feature (62) for the coating and controlling the spray process (64, 68)
to have at least one of an in-flight particle temperature distribution
and an in-flight particle velocity distribution predicted to produce the
dominant feature. One aspect allows for adjusting (64, 68) the at least
one distribution to cause the distribution to shift from an in-flight
Gaussian particle distribution to an in-flight non-Gaussian particle
distribution. It may be determined whether the dominant feature for the
coating is deposited within acceptable limits (66) and adjusting the at
least one in-flight particle distribution (68) if the dominant feature
for the coating is not deposited within acceptable limits. One aspect
allows for depositing on the substrate a spray jet of particles having a
bimodal distribution of particle temperature and a bimodal distribution
of particle velocity. These bimodal distributions may be tailored or
adjusted (64,68) toachieve a desired dominant feature of the coating.
Aplurality of particle distributions may be evaluated (60) to determine
at least one respective dominant feature that is a characteristic of a
coating applied using the respective evaluated particle distribution. At
least one dominant feature to be a characteristic of the coating may be
determined (62) and at least one of the evaluated particle distributions
predicted to produce the at least one dominant feature may be selected
(63) to form the non-Gaussian distribution. |
|
20040247795 |
Jun. 4, 2003 |
|
METHOD OF PRODUCING A COATED VALVE RETAINER |
|
DOWNLOAD |
Mark Thomas Endicott |
During engine operation, valve retainers and valve springs are
constantly rubbing and impacting each other resulting in heat and wear.
The purpose of this invention is to provide a surface coating onto the
valve retainer to reduce the friction with the valve spring and thus
improve durability. Specifically, this invention teaches a method to
thermally apply coatings to the surface of the valve retainer. Although
typically fabricated from steel, the usage of lighter weight titanium
valve retainers is increasing for high performance, or racing engines.
The reduced mass allows valves to move more readily and requires less
spring pressure to operate, producing more power and a faster revving
engine, however titanium is typically not as wear resistant as the steel
it replaces. In one embodiment, a porous molybdenum or other oleophilic
metal is applied to the surface of the valve retainer. In another
embodiment, hard, dense coatings of cermets, carbides, and super alloys
are applied as coatings to valve retainers. |
|
Randall John Wischhusen |
|
20050120957 |
Jan. 18, 2005 |
Flame Spray Industries, Inc. |
PLASMA SPRAY METHOD AND APPARATUS FOR APPLYING A COATING UTILIZING
PARTICLE KINETICS |
|
DOWNLOAD |
Keith A. Kowalsky |
A method of operation of a plasma torch and the plasma apparatus to
produce a hot gas jet stream directed towards a workpiece to be coated
by first injecting a cold high pressure carrier gas containing a powder
material into a cold main high pressure gas flow and then directing this
combined high pressure gas flow coaxially around a plasma exiting from
an operating plasma generator and converging directly into the hot
plasma effluent, thereby mixing with the hot plasma effluent to form a
gas stream with a net temperature based on the enthalpy of the plasma
stream and the temperature and volume of the cold high pressure
converging gas, establishing a net temperature of the gas stream at a
temperature such that the powdered material will not melt or soften, and
projecting the powder particles at high velocity onto a workpiece
surface. The improvement resides in mixing a cold high pressure carrier
gas with powder material entrained in it, with a cold high pressure gas
flow of gas prior to mixing this combined gas flow with the plasma
effluent which is utilized to heat the combined gas flow to an elevated
temperature limited to not exceeding the softening point or melting
point of the powder material. The resulting hot high pressure gas flow
is directed through a supersonic nozzle to accelerate this heated gas
flow to supersonic velocities, thereby providing sufficient velocity to
the particles striking the workpiece to achieve a kinetic energy
transformation into elastic deformation of the particles as they impact
the onto the workpiece surface and forming a dense, tightly adhering
cohesive coating. Preferably the powder material is of metals, alloys,
polymers and mixtures thereof or with semiconductors or ceramics and the
powder material is preferably of a particle size range exceeding 50
microns. |
|
Daniel R. Marantz |
|
20050235493 |
Apr. 22, 2004 |
Siemens Westinghouse Power Corporation |
IN-FRAME REPAIR OF GAS TURBINE COMPONENTS |
|
DOWNLOAD |
Vinod Philip |
Amethod for in-frame repairing of a thermal barrier coating (12) on a
gas turbine component includes cleaning a desired surface portion (10)
of the component without removing the component from the gas turbine.
The method also includes roughening the surface portion in-frame,
applying a bond coat (68) to the surface portion in-frame, and applying
a ceramic topcoat (70) to the bond coat, in-frame. A system (28) for
cleaning the surface portion in-frame includes an abrasive media (34)
having a state change characteristic occurring at a temperature lower
than an operating temperature of the gas turbine so that the abrasive
media changes from a solid state to another state allowing the media to
exit the gas turbine during operation. The system also includes an
abrasive media sprayer (36) to direct a spray of the abrasive media at
the desired surface portion. |
|
Brij Seth |
|
Paul Zombo |
|
Dennis Nagle |
|
20050242158 |
Apr. 28, 2004 |
The Boeing Company |
ALUMINUM COATING FOR THE CORROSION PROTECTION OF WELDS |
|
DOWNLOAD |
David R. Bolser |
A method for coating and an associated assembly including such a coating
are provided. The assembly includes a workpiece defining a weld portion,
such as a friction weld joint and a heat affected zone. A coating is
disposed on the weld portion to at least partially cover the weld
portion, thereby providing enhanced corrosion resistance to the
workpiece. |
|
20050252450 |
24-May-05 |
Flame Spray Industries, Inc. |
PLASMA SPRAY METHOD AND APPARATUS FOR APPLYING A COATING UTILIZING
PARTICLE KINETICS |
|
DOWNLOAD |
Keith A. Kowalsky |
A method of operation of a plasma torch and the plasma apparatus to
produce a hot gas jet stream directed towards a workpiece to be coated
by first injecting a cold high pressure carrier gas containing a powder
material into a cold main high pressure gas flow and then directing this
combined high pressure gas flow coaxially around a plasma exiting from
an operating plasma generator and converging directly into the hot
plasma effluent, thereby mixing with the hot plasma effluent to form a
gas stream with a net temperature based on the enthalpy of the plasma
stream and the temperature and volume of the cold high pressure
converging gas, establishing a net temperature of the gas stream at a
temperature such that the powdered material will not melt or soften, and
projecting the powder particles at high velocity onto a workpiece
surface. The improvement resides in mixing a
cold high pressure carrier gas with powder material entrained in it,
with a cold high pressure gas flow of gas prior to mixing this combined
gas flow with the plasma effluent which is utilized to heat the combined
gas flow to an elevated temperature limited to not exceeding the
softening point or melting point of the powder material. The resulting
hot high pressure gas flow is directed through a supersonic nozzle to
accelerate this heated gas flow to supersonic velocities, thereby
providing sufficient velocity to the particles striking the workpiece to
achieve a kinetic energy transformation into elastic deformation of the
particles as they impact the onto the workpiece surface and forming a
dense, tightly adhering cohesive coating. Preferably the powder material
is of metals, alloys, polymers and mixtures thereof or with
semiconductors or ceramics and the powder material is preferably of a
particle size range exceeding 50 microns. The system also includes a
rotating member for coating concave surfaces and internal bores or other
such devices which can be better coated using rotation. |
|
Daniel R. Marantz |
|
20060045785 |
Aug. 30, 2004 |
|
METHOD FOR REPAIRING TITANIUM ALLOY COMPONENTS |
|
DOWNLOAD |
Yiping Hu |
A method for repairing a titanium alloy surface of a turbine component
includes the step of cold gas-dynamic spraying a powder material
comprising at least one titanium alloy directly on the titanium alloy
surface. The method may further include the steps of hot isostatic
pressing the cold gas-dynamic sprayed turbine component, and performing
a separate heat treating step after the hot isostatic pressing. Thus,
the cold gas-dynamic spray process and post-spray processing can be
employed to effectively repair degraded areas on compressor turbine
components. |
|
Federico Renteria |
|
Christopher L. Cahoon |
|
Margaret Floyd |
|
20060051502 |
Sep. 8, 2004 |
|
METHODS FOR APPLYING ABRASIVE AND ENVIRONMENT-RESISTANT COATINGS ONTO
TURBINE COMPONENTS |
|
DOWNLOAD |
Yiping Hu |
A method for coating a surface of a turbine component with an
environment-resistant and wear-resistant material includes the step of
cold gas-dynamic spraying a powder material on the turbine component
surface, the powder material comprising a mixture of MCrAlY powder and
an abrasive powder such as cubic boron nitride, diamond, carbides, and
oxides, with M being selected from Ni, Co and mixtures thereof. The
method can further include the step of heat treating the turbine
component after the cold gasdynamic spraying. Thus, the present
invention can be employed to greatly improve the performance and the
durability of HPT components, and dramatically prolong their service
life. |
|
William F. Hehmann |
|
Federico Renteria |
|
20060068087 |
Sep. 26, 2003 |
|
DIRECT WRITING OF METALLIC CONDUCTOR PATTERNS ON INSULATING SURFACES |
|
DOWNLOAD |
Richard Gambino |
A method for direct writing an electrically conductive metallic feature
on an insulating substrate comprises creating a gas jet comprising
metallic particles (301), ejecting the gas jet comprising metallic
particles through a straight bore tube (302), and impacting the gas jet
comprising metallic particles onto a substrate to impinge the metallic
particles on the substrate to form the electrically conductive metallic
feature (303). |
|
Robert Greenlaw |
|
Shaun Kubik |
|
Jon Longtin |
|
Joshua Margolies |
|
Sanjay Sampath |
|
20060081174 |
Dec. 27, 2004 |
Doben Limited |
VACUUM NOZZLE FOR SPRAY SYSTEM |
|
DOWNLOAD |
Zygmunt Baran |
A cold spray system includes a spray nozzle for depositing material onto
a substrate. A collection assembly at least partially surrounds the
spray nozzle for vacuuming undepositive material and gases in the work
area. The collection assembly includes a transparent collection tube at
an end portion of the collection assembly to provide visibility to the
work area. The collection assembly includes a shield having a flange
that extends radially outwardly from the collection assembly and is
generally parallel to a substrate. An angled portion of the shield
extends from the collection assembly. A radius portion adjoins the
flange and the angled portion. Aring is spaced between the spray nozzle
and the shield. An inner surface of the ring deflects material that
typically would otherwise not become adhered to the substrate back into
the collection assembly to minimize the material that must be vacuumed
at the substrate. A curved surface of the ring extends from a surface
spaced from the substrate toward the shield to provide a smooth
transition for materials flowing along the substrate back into the
collection assembly. |
|
20060090593 |
Nov. 3, 2004 |
|
COLD SPRAY FORMATION OF THIN METAL COATINGS |
|
DOWNLOAD |
Junhai Liu |
The invention relates to an adaptation of the cold spray process to
provide a method of coating fine metal particles, including aluminum and
copper, onto a work piece. In one embodiment, the invention is a metal
agglomerated hard sphere composition capable of providing about a 1
micron or thicker coating of a metal on a work piece in a cold spray
process. In another embodiment the invention is a method of coating
metal particles, including metal particles having a particle size of
about 0.01 to about 10 micron, onto a work piece. The method of the
invention circumvents many of the problems associated with cold spray
processing of very fine particles. |
|
20060093888 |
Nov. 1, 2004 |
|
METHOD OF FABRICATING CORROSION-RESISTANT BIPOLAR PLATE |
|
DOWNLOAD |
Gayatri Vyas |
A method of fabricating a corrosion-resistant and inexpensive bipolar
plate for a fuel cell is disclosed. The method includes providing a
bipolar plate substrate and coating a corrosion-resistant coating on the
bipolar plate substrate using a kinetic spray process. |
|
Mahmoud H. Abd Elhamid |
|
Youssef M. Mikhail |
|
Richard H. Blunk |
|
20060105113 |
Nov. 21, 2005 |
|
METHOD OF PRODUCING A COATED VALVE RETAINER |
|
DOWNLOAD |
Mark Thomas Endicott |
During engine operation, valve retainers and valve springs are
constantly rubbing and impacting each other resulting in heat and wear.
The purpose of this invention is to provide a surface coating onto the
valve retainer to reduce the friction with the valve spring and thus
improve durability. Specifically, this invention teaches a method to
thermally apply coatings to the surface of the valve retainer. Although
typically fabricated from steel, the usage of lighter weight titanium
valve retainers is increasing for high performance, or racing engines.
The reduced mass allows valves to move more readily and requires less
spring pressure to operate, producing more power and a faster revving
engine, however titanium is typically not as wear resistant as the steel
it replaces. In one embodiment, a porous molybdenum or other oleophilic
metal is applied to the surface of the valve retainer. In another
embodiment, hard coatings of cermets, carbides, and super alloys are
applied as coatings to valve retainers. |
|
Randall John Wischhusen |
|
20060108031 |
Nov. 23, 2004 |
United Technologies Corporation |
COLD GAS DYNAMIC SPRAYING OF HIGH STRENGTH COPPER |
|
DOWNLOAD |
Jeffrey D. Haynes |
A process for forming an article, such as a combustion chamber liner,
comprises the steps of providing a mandrel formed from a material, such
as an aluminum containing material, having a net shape of the article to
be made, depositing a powdered metal material onto the mandrel without
melting the powdered metal material, and removing the material forming
the mandrel to leave a free standing monolithic article. In a preferred
embodiment of the present invention, the powdered metal material
comprises powdered GRCop-84. Alternatively, the powdered metal material
may be GRCop-42. |
|
20060108601 |
Nov. 22, 2005 |
Fuji Electric Holdings Co.,
Ltd., |
INSULATING SUBSTRATE AND SEMICONDUCTOR DEVICE |
|
DOWNLOAD |
Kenji Okamoto |
An insulating substrate includes a metal base as a base member, an
insulating layer which is a room temperature, aerosol deposited shock
solidification film formed on the metal base, and a circuit pattern
which is a cold sprayed thermal spray coating formed on the insulating
layer. A semiconductor device incorporates the insulating substrate, and
thereby has improved heat radiation characteristics. |
|
20060121187 |
Dec. 3, 2004 |
|
VACUUM COLD SPRAY PROCESS |
|
DOWNLOAD |
Jeffrey D. Haynes |
A method for depositing a metallic material onto a substrate comprises
the steps of placing the substrate in a vacuum chamber, inserting a
spray gun nozzle into a port of the vacuum chamber, and depositing a
powdered metallic material onto a surface of the substrate without
melting the powdered metal material. The depositing step comprises
accelerating particles of the powdered metal materials within the vacuum
chamber to a velocity so that upon impact the particles plastically
deform and bond to a surface of the substrate. |
|
Douglas Alan Hobbs |
|
20060134320 |
Dec. 21, 2004 |
United Technologies Corporation |
STRUCTURAL REPAIR USING COLD SPRAYED ALUMINUM MATERIALS |
|
DOWNLOAD |
Andrew DeBiccari |
A method for repairing components comprises the steps of providing a
component having a defect to be repaired and depositing an aluminum
containing repair material over an affected area on a surface of the
component so that the repair material plastically deforms and bonds to
the affected area upon impact with the affected area and thereby covers
the affected area. |
|
Jeffrey D. Haynes |
|
David A. Rutz |
|
20060134321 |
Dec. 22, 2004 |
United Technologies Corporation |
BLADE PLATFORM RESTORATION USING COLD SPRAY |
|
DOWNLOAD |
Andrew DeBiccari |
A process for restoring a worn edge of a component used in an engine is
provided. The process comprises providing a component with a worn edge,
and depositing at least one layer of powder metal material onto the worn
edge using a non-oxidizing carrier gas so that the powder metal material
plastically deforms without melting and bonds to the worn edge upon
impact with the worn edge. |
|
Jeffrey D. Haynes |
|
20060141144 |
Feb. 17, A2912006 |
National Institute Of Advanced Industrial Science And Technology, Toto
Ltd. |
METHOD FOR MANUFACTURING COMPOSITE STRUCTURE BODY |
|
DOWNLOAD |
Hironori Hatono |
A method for manufacturing a composite structure body, comprising the
steps of bombarding brittle material fine particles and ductile material
fine particles separately or simultaneously against a surface of a
substrate with high velocities such that an anchor portion biting said
substrate surface is formed; the brittle material fine particles are
simultaneously distorted or fractured by impact of the bombardment;
mutual rejoining of the fine particles is made through intermediary of a
newly generated active surface formed by the distortion or fracture; and
thereby forming a structure body, above the anchor portion, in which
crystals of the brittle material and crystals andlor microstructures of
the ductile material fine particles are dispersed. |
|
Masakatsu Kiyohara |
|
Katsuhiko Mori |
|
Tatsuro Yokoyama |
|
Atsushi Yoshida |
|
Tomokazu Ito |
|
Jun Akedo |
|
20060157274 |
Nov. 8, 2005 |
|
WAFER-LEVEL HERMETIC MICRO-DEVICE PACKAGES |
|
DOWNLOAD |
David H Stark |
A method for manufacturing a hermetically sealed micro-device package
encapsulating a micro-device. The package includes a transparent window
allowing light to pass into and out of a cavity containing the
micro-device. A first frame-attachment area is prepared on semiconductor
substrate having a micro-device operably disposed thereupon, the first
frame-attachment area having a plan that circumscribes the micro-device.
A second frame-attachment area is prepared on a sheet of transparent
material, the second frame-attachment area having a plan that
circumscribes a window aperture portion of the sheet. A frame/spacer is
positioned between the semiconductor substrate and the sheet, the
frame/spacer including a continuous sidewall having a plan on one side
substantially corresponding to, and substantially in register with, the
plan of the first frame-attachment area, having a plan on the opposite
side substantially corresponding to, and substantially in register with,
the plan of the second frame-attachment area, and having a height that
exceeds the height of the micro-device. Next the substrate, frame/spacer
and window are bonded together to form a hermetically sealed package
encapsulating the micro-device in a cavity below the window aperture
portion of the transparent sheet. |
|
20060159997 |
Apr. 19, 2005 |
|
ELECTRODE FOR LITHIUM SECONDARY BATTERY AND LITHIUM SECONDARY BATTERY |
|
DOWNLOAD |
Takuya Sunagawa |
There is provided an electrode for a lithium secondary battery where
particles, composed of an active material capable of occluding and
releasing lithium, are arranged on a current collector, the active
material particle being directly bonded to the surface of the current
collector in a state where the bottom of the active material particle is
imbedded in a concave portion formed on the surface of the current
collector. A second particle layer may be provided on a first particle
layer comprising the active material particles directly bonded to the
surface of the current collector. |
|
Yasuyuki Kusumoto |
|
Shin Fujitani |
|
Kensuke Nakatani |
|
Muneto Kobayashi |
|
20060165546 |
Jan. 23, 2006 |
Aisan Kogyo Kabushiki Kaisha |
METHOD AND APPARATUS FOR MANUFACTURING THREE-DIMENSIONAL OBJECTS |
|
DOWNLOAD |
Shigeki Yamada |
The present invention teaches a method and an apparatus for
manufacturing a three-dimensional object having a smooth outer surface,
without any step of removing a surface layer each time a sintered layer
is formed so as to manufacture a three-dimensional object consisting of
integrally built-up sintered layers. The method may include the steps
of: (i) supplying powder particles (10) onto a moving area while heating
the powder particles (10) with heat (20) from a high-density energy heat
source so as to form a sintered layer (16); and (ii) supplying powder
particles 10 onto a moving area on the sintered layer while heating the
powder particles (10) with heat (20) from the high-density energy heat
source so as to form another sintered layer (18) integrally on the
sintered layer (16), wherein the step (ii) is repeated a predetermined
number of times. |
|
Hiroyuki Hara |
|
20060166020 |
Jan. 26, 2005 |
Honeywell International Inc. |
HIGH STRENGTH AMORPHOUS AND MICROCRYSTALINE STRUCTURES AND COATINGS |
|
DOWNLOAD |
Derek Raybould |
The present invention thus provides an improved method for coating
turbine engine components. The method utilizes a cold high velocity gas
spray technique to coat turbine blades, compressor blades, impellers,
blisks, and other turbine engine components. These methods can be used
to coat a variety of surfaces thereon, thus improving the overall
durability, reliability and performance of the turbine engine itself.
The method includes the deposition of powders of alloys of nickel and
aluminum wherein the powders are formed so as to have an amorphous
microstructure. Layers of the alloys may be deposited and built up by
cold high velocity gas spraying. The coated items displayed improved
characteristics such as hardness, strength, and corrosion resistance. |
|
Murali N Madhava |
|
20060172073 |
Feb. 1, 2005 |
U.S. Government |
METHODS FOR PRODUCTION OF FGM NET SHAPED BODY FOR VARIOUS APPLICATIONS |
|
DOWNLOAD |
Joanna R Groza |
Methods for the production of functionally graded material (FGM) are
provided. FGM is processed by powder cold spraying ceramic-metal layers,
the final shape is pre-pressed by cold isostatic pressing and is then
sintered using field activated sintering technique (FAST). The FGM
materials can be used for medical applications. |
|
Vladimir Kodash |
|
20060191406 |
Feb. 28, 2005 |
Caterpillar |
CYLINDER ROD WITH POSITION SENSOR SURFACE MARKINGS |
|
DOWNLOAD |
Trent S Kucher |
A cylinder rod with wear-resistant surface markings is provided. The
cylinder rod may include a rod substrate, a thermal-spray coating
disposed on a surface of the substrate, and one or more surface markings
disposed on the coating at predetermined locations along the length of
the cylinder rod. |
|
Karen R Raab |
|
Xiangyang Jiang |
|
20060201418 |
Jul. 22, 2005 |
|
NOZZLE FOR COLD SPRAY AND COLD SPRAY APPARATUS USING SAME |
|
DOWNLOAD |
Kyung-hyun Ko |
Disclosed is a nozzle for cold spray and a cold spray apparatus using
the same. The nozzle for cold spray includes a hollow-type nozzle
section. The nozzle section includes a convergence inlet section in
which the cross-sectional area is converging, a throat area connected to
the convergence end point of the inlet section, and an outlet section
connected to the end point of the throat area. The nozzle for cold spray
is provided with a spray tube located inside the convergence inlet
section, the spray tube having a spray hole formed at its end point in
such a way as to be placed at the throat area or the outlet section
beyond the throat area. The speed of the powder flow at the outlet end
point of the outlet section reaches 300-1,200 m/s. |
|
Ha-yong Lee |
|
Jae-hong Lee |
|
Jae-jeong Lee |
|
Young-ho Yu |
|
20060201419 |
May 18, 2006 |
National Institute Of Advanced Industrial Science And Technology, Toto
Ltd. |
APPARATUS FOR FORMING COMPOSITE STRUCTURES |
|
DOWNLOAD |
Jun Akedo |
A composite structure forming apparatus adapted to ejecting and causing
an aerosol generated by scattering brittle material fine particles in a
gas to collide with a substrate at high speed to form a structure made
of the brittle material. The apparatus includes an aerosol generator for
generating the aerosol, a nozzle for ejecting the aerosol, a shredder
for shredding the brittle particles cohering in the aerosol and
preventing cohesion of the brittle material fine particles, and a
classifier for classifying the brittle material fine particles in the
aerosol. The apparatus also includes a pretreatment device for creating
internal strain in the brittle material fine particles, and a position
control device for controlling the position of the nozzle relative to
the substrate. The apparatus further includes a container having a sieve
and a vibration device, and one or more of these components may be
associated with the aerosol generator. |
|
Tomokadsu Ito |
|
Tatsuro Yokoyama |
|
Katsuhiko Mori |
|
Hironori Hatono |
|
Masakatsu Kiyohara |
|
Yuji Aso |
|
20060201934 |
May 8, 2006 |
Leoni Aktiengesellschaft |
ELECTRICAL CONTACT CONNECTION AND METHOD FOR FORMING SUCH A CONTACT
CONNECTION |
|
DOWNLOAD |
Gerhard Reichinger |
In order to make it possible to produce a secure and permanent contact
connection between an electrical conductor made from a soft material, in
particular an aluminum conductor, and a contact element made from a
harder material, the conductor is encapsulated at least partially in a
contact region by an electrically conductive material. The electrically
conductive material is harder than the soft material of the conductor.
The electrically conductive material is applied with the aid of a
thermal spraying process, with the result that there is a pressure-free
electrical connection between the soft material and the sprayed-on
material. Electrical contact is made with the contact element indirectly
via the sprayed-on material. The thermal encapsulation by the spraying
in the contact region makes it possible for a reliable electrical
contact to be made even in the case of soft materials having a tendency
towards cold flow. |
|
20060207080 |
Mar. 17, 2005 |
|
PROCESS OF REFURBISHING BRAKE COMPONENTS |
|
DOWNLOAD |
Robert A Keate |
A method of refurbishing components such as brake rotors and drums is
disclosed. The method may involve identifying, sorting and cleaning used
or worn components. The components may then be blasted with an abrasive
material to prepare them for a metal deposition process. Metal may then
be added to the components using an arc spray gun, for example. The
component may then be cryogenically treated to improve the wear
characteristics of the component. The component may then be machined to
place the component within a specified configuration. Components may be
refurbished repeatedly in this manner so as to utilize resources more
efficiently and reduce waste. Moreover, the components may exhibit
improved wear characteristics over components manufactured by other
methods. |
|
20060207094 |
Mar. 17, 2005 |
Siemens Westinghouse Power Corporation |
COLD SPRAY PROCESS FOR SEAL APPLICATIONS |
|
DOWNLOAD |
David B Allen |
A method of forming an interstage seal including removing a diaphragm
seal box (14) from a gas turbine compressor assembly (10) and removing a
labyrinth sealing member (12) from the diaphragm seal box (14). An
abradable material layer (34) may be deposited on the diaphragm seal box
(14). A spray gun may be mounted in relation to an engine disk (16) of
the gas turbine compressor assembly (10) for cold-spraying a quantity of
particles toward the engine disk (16). The particles may be sprayed at a
velocity sufficiently high to cause at least a portion of the quantity
of particles to adhere to the engine disk (16). The spray gun may be
controlled to deposit a quantity of particles on the compressor disk
(16) to form a geometry (32) that will abrade the abradable material
layer (34) during operation of the gas turbine compressor assembly (10).
The geometry (32) abrading the abradable material layer (34) forms an
interstage seal. Rotation of the engine disk (16) within the gas turbine
compressor assembly (10) may be controlled during the step of
controlling the spray gun. The diaphragm seal box (14) may be
reinstalled within the gas turbine compressor assembly (10) so that the
geometry (32) aligns with the abradable material layer (34). |
|
Ramesh Subramanian |
|
20060216428 |
Mar. 23, 2005 |
United Technologies Corporation |
APPLYING BOND COAT TO ENGINE COMPONENTS USING COLD SPRAY |
|
DOWNLOAD |
Andrew DeBiccari |
A process for applying a coating to a component used in an engine is
provided. The process includes the steps of providing a component with
at least one surface to be coated, and depositing at least one layer of
powder coating material onto the at least one surface using a
non-oxidizing carrier gas so that the powder coating material
plastically deforms without melting and bonds to the at least one
surface upon impact with the at least one surface. The process of the
present invention has particular utility in applying bond coats to
airfoil portions of turbine blades or vanes and to applying bond coats
to combustion chamber liners. |
|
Melvin Freling |
|
Jeffrey D Haynes |
|
20060219329 |
Mar. 29, 2005 |
Honeywell International Inc. |
REPAIR NICKEL-BASED SUPERALLOY AND METHODS FOR REFURBISHMENT OF GAS
TURBINE COMPONENTS |
|
DOWNLOAD |
Yiping Hu |
A nickel-based superalloy includes, in terms of weight, about 0.06% to
about 0.10% carbon, about 6.0% to about 6.4% aluminum, about 5.8% to
about 6.3% tantalum, about 6.5% to about 7.0% chromium, about 8.8% to
about 9.3% cobalt, about 0.6% to about 1.0% molybdenum, about 2.4% to
about 2.8% rhenium, about 4.8% to about 5.3% tungsten, about 0.3% to
about 0.80% hafnium, about 0.01% to about 0.03% zirconium, about 0.10%
to about 0.18% silicon, and nickel. A method for repairing a surface of
a turbine component includes the step of applying the nickel-based
superalloy to a damaged area of the component surface. Post-deposition
processes are also performed as necessary. |
|
Richard L Bye |
|
20060219330 |
Mar. 29, 2005 |
Honeywell International Inc. |
NICKEL-BASED SUPERALLOY AND METHODS FOR REPAIRING GAS TURBINE COMPONENTS |
|
DOWNLOAD |
Yiping Hu |
A nickel-based superalloy includes, in terms of weight, in terms of
weight, about 0.08% to about 0.12% carbon, about 6.0% to about 6.4%
aluminum, about 5.8% to about 6.3% tantalum, about 6.5% to about 7.0%
chromium, about 9.3% to about 9.8% cobalt, about 1.3% to about 1.7%
molybdenum, about 2.4% to about 2.8% rhenium, about 3.8% to about 4.3%
tungsten, about 0.9% to about 1.3% hafnium, about 0.01% to about 0.03%
zirconium, up to about 0.10% silicon, and nickel. A method for repairing
a surface of a turbine component includes the step of applying the
nickel-based superalloy to a damaged area of the component surface, and
post-deposition processes. |
|
Richard L Bye |
|
20060222776 |
Mar. 29, 2005 |
Honeywell International Inc. |
ENVIRONMENT-RESISTANT PLATINUM ALUMINIDE COATINGS, AND METHODS OF
APPLYING THE SAME ONTO TURBINE COMPONENTS |
|
DOWNLOAD |
Murali N Madhava |
In a method for coating a surface of a turbine component with an
environment-resistant aluminide, a coating is formed by cold gas-dynamic
spraying a powder material on the turbine component surface, the powder
material comprising aluminum, platinum, and at least one additional
metal selected from the group consisting of nickel, chromium, hafnium,
silicon, yttrium, rhenium, zirconium, cobalt, and tantalum. After
forming the coating, at least one thermal diffusion treatment is
performed on the turbine component to metallurgically homogenize the
coating and thereby form an aluminide coating that includes by weight
about 12 to about 30% aluminum, up to about 50% platinum, about 2 to
about 25% chromium, about 1 to about 5% hafnium, about 1 to about 5%
silicon, about 0.1 to about 1% yttrium, and about 1 to about 3% Zr, and
nickel. |
|
Yiping Hu |
|
Derek Raybould |
|
Trinh-Le Huu-Duc |
|
Siu-Ching D Lui |
|
20060222862 |
May. 22, 2006 |
National Institute Of Advanced Industrial Science And Technology, Toto
Ltd. |
BRITTLE MATERIAL FINE PARTICLES WITH INTERNAL STRAIN FOR USE IN AEROSOL
DEPOSITION METHOD |
|
DOWNLOAD |
Jun Akedo |
A material composed of brittle material fine particles, such as ceramic
or metalloid fine particles, for forming a composite structure on a
substrate surface. The brittle material is pretreated to achieve a
specific size range of fine particles and to develop a desired range of
internal strain therein. The brittle material fine particles are adapted
to form an aerosol with a gas stream, and when the aerosol is ejected to
collide with a substrate surface, this causes collision of brittle
material fine particles with a substrate surface thus imparting a
mechanical impact to the fine particles. Such mechanical impact
fractures or deforms the particles, and thereby generates an active new
surface for brittle material fine particles after being fractured or
deformed. |
|
Tomokadsu Ito |
|
Tatsuro Yokoyama |
|
Katsuhiko Mori |
|
Hironori Hatono |
|
Masakatsu Kiyohara |
|
Yuji Aso |
|
20060233951 |
Apr. 14, 2005 |
United Technologies Corporation |
METHOD AND SYSTEM FOR CREATING FUNCTIONALLY GRADED MATERIALS USING COLD
SPRAY |
|
DOWNLOAD |
Andrew DeBiccari |
A method and system for depositing multiple materials onto a substrate
is described. The method broadly comprises the steps of providing a
source of a first powder material to be deposited, providing a source of
a second powder material to be deposited, and sequentially depositing
the first powder material and the second powder material onto the
substrate at a velocity sufficient to deposit the materials by
plastically deforming the materials without metallurgically transforming
the particles of powder forming the materials. |
|
Jeffrey D Haynes |
|
20060234575 |
Apr. 13, 2005 |
|
THERMALLY SPRAYED PROTECTIVE COATING FOR INDUSTRIAL AND ENGINEERED
FABRICS |
|
DOWNLOAD |
Joseph Salitsky |
A fabric or belt and a method for forming such a fabric or belt,
including a base support structure and at least one coating with the
coating being applied by a thermal spray process. |
|
Bo-Christer Aberg |
|
20060240192 |
Apr. 25, 2005 |
Honeywell International Inc. |
MAGNESIUM REPAIR AND BUILD UP |
|
DOWNLOAD |
Derek Raybould |
The present invention provides methods and materials for use in applying
a coating on a surface of a magnesium component. The method includes the
steps of: accelerating a coating powder to a velocity of between about
500 to about 1200 meters/second, wherein the coating powder comprises a
material selected from the group consisting of aluminum, aluminum
alloys, titanium, titanium alloys, and composites; directing the coating
powder through a convergent-divergent nozzle onto the surface of the
magnesium component; and forming a coating on the surface of the
magnesium component so as to substantially cover the surface of the
magnesium component. The coating thickness may be between approximately
0.1 to approximately 1.0 mm. |
|
Murali N Madhava |
|
Vincent Chung |
|
Timothy R Duffy |
|
Margaret M Floyd |
|
20060243256 |
Apr. 14, 2003 |
Alcoa Technical Center |
SURFACE REACTOR |
|
DOWNLOAD |
Wolfgang Hornig |
A surface reactor includes a copper-tin alloy for converting unsaturated
hydrocarbons contained in propellants and fuels. The surface reactor is
configured in one-piece from a long chip or wire-shaped body. The
surface reactor is configured from the alloy or from a support material
that has been appropriately shaped and coated with the alloy. |
|
20060243593 |
Apr. 29, 2005 |
|
APPARATUS AND METHOD FOR IMPROVING CONTACT BETWEEN A WEB AND A ROLL |
|
DOWNLOAD |
Kenneth A Bowman |
This invention discloses a conductor roll that is surrounded by a crown
that extends along a substantial portion of the length of the conductor
roll. The crown is designed to compensate for the deflection of the
conductor roll when the conductor roll is placed under a load. |
|
John L Pracht |
|
Bernard J Becker |
|
20060246297 |
Apr. 27, 2005 |
Ferro Corporation |
PROCESS FOR STRUCTURING SELF-CLEANING GLASS SURFACES |
|
DOWNLOAD |
George E Sakoske |
A plasma spray process for structuring self-cleaning glass surfaces and
self-cleaning glass surfaces formed according to the process. Molten or
heat softened particles of inorganic material are plasma spray deposited
onto the surface of a substrate to create a micro-rough surface. If
desired, a hydrophobic top coating layer can optionally be applied to
the micro-rough surface. The micro-structured surface formed according
to the invention is durable and self-cleaning. |
|
Martin Baumann |
|
Enos A Axtell III |
|
20060249022 |
Nov. 21, 2003 |
Praxair, Inc. |
GAS SUPPLY AND RECOVERY FOR METAL ATOMIZER |
|
DOWNLOAD |
Scot Eric Jaynes |
The invention uses helium and helium recovery purification equipment to
remove impurities from the process enclosed equipment such as a melt
chamber and atomization tower. An above atmosphere pressure argon/helium
exchange can create the argon atmosphere needed for atomization. |
|
Mark Kleis |
|
Jaak Van den Sype |
|
20060251805 |
Feb. 1, 2006 |
Solidica |
COMBINATION HYBRID KINETIC SPRAY AND CONSOLIDATION PROCESSES |
|
DOWNLOAD |
Dawn White |
Solid-state bonding technologies are combined with other solid-state
consolidation techniques to create new processes, applications, and
structures. One embodiment uses metal or plastic spraying techniques
with the intention of only partially bonding the droplets to the
substrate, while employing a secondary process such as ultrasonic and/or
electrical resistance consolidation to achieve complete agglomeration
and eliminate porosity. This opens new opportunities with regard to
materials, powder types, applications, and automated machinery. Some
examples of these hybrids and their applications are provided, however,
along with the identification of other combinations. |
|
Ken E Johnson |
|
20060251823 |
Jul. 7, 2006 |
Delphi Technologies, Inc |
KINETIC SPRAY APPLICATION OF COATINGS ONTO COVERED MATERIALS |
|
DOWNLOAD |
Thomas H Van Steenkiste |
Disclosed is a process for applying a kinetic spray coating of powder
particles onto a substrate covered in a plastic-type material without
first removing the plastic-type material. In one use of the process a
mask is used to enable a single kinetic spray pass to both remove the
plastic covering and bind particles having average nominal diameters of
from 60 to 250 microns to the underlying substrate. In another use of
the process the particles have an average nominal diameter of from 250
to 1400 microns and the use of a mask is optional because the particles
can penetrate the plastic material and bind directly to the substrate.
The process finds special use in forming electrical connections or
solderable pads anywhere along the length of a flexible circuit. |
|
Daniel W Gorkiewicz |
|
John R Smith |
|
Martin Stier |
|
George A Drew |
|
20060255100 |
May. 10, 2005 |
Honeywell International Inc |
METHOD OF REPAIR OF THIN WALL HOUSINGS |
|
DOWNLOAD |
David A Payne |
The present invention provides methods and materials for use in
repairing a worn component having thin walls. One kind of thin wall may
be the wall of a cylindrical portion of the component where such wall
has a worn inner surface and an opposite outer surface. The method
includes the steps of preparing the outer surface of the component for
cold spraying; cold spraying material onto the outer surface so as to
form a strengthening coating; reaming the inner surface so as to create
a repair surface with a repair diameter greater than the inner diameter;
and installing an insert on the repair surface. The thickness of the
coating is selected so as to impart a desired degree of strength to the
wall. The method allows the repair of expensive aluminum castings that
would otherwise, because of the thin wall construction, not be suitable
for repair. |
|
Paul E Garland |
|
20060258055 |
Feb. 22, 2006 |
Fuji Electric Holdings Co., Ltd |
WIRING BOARD AND METHOD OF MANUFACTURING THE SAME |
|
DOWNLOAD |
Kenji Okamoto |
A wiring board has a circuit pattern that includes metal foil attached
to an insulating layer, and a built-up circuit pattern disposed on top
of the metal foil circuit pattern. The built-up circuit pattern is an
increased thickness laminate of cold spray processed metal material.
Even when a power semiconductor is mounted on the built-up circuit
pattern, the heat that is generated by losses therein can be diffused by
the built-up circuit pattern. The wiring board has excellent heat
dissipation, can be manufactured by a small number of process steps, and
is of low cost. |
|
20060260126 |
May. 17, 2005 |
General Electric Company |
METHOD FOR MAKING A COMPOSITIONALLY GRADED GAS TURBINE DISK |
|
DOWNLOAD |
Jon Raymond Groh |
A compositionally graded gas turbine disk is made by preparing a
rotationally symmetric radially inner segment of a gas turbine disk
preform, rotating the inner segment about a central axis, spray applying
a radially outer-segment material onto the radially inner segment as it
rotates about the central axis, preferably achieving a gradual
transition in composition, and thereafter further processing the gas
turbine disk preform to produce the compositionally graded gas turbine
disk. |
|
Eric A Ott |
|
Robert E Schafrik |
|
Daniel D Krueger |
|
20060269685 |
May. 31, 2005 |
Honeywell International Inc |
METHOD FOR COATING TURBINE ENGINE COMPONENTS WITH HIGH VELOCITY
PARTICLES |
|
DOWNLOAD |
Derek Raybould |
A method for coating a surface of a metal component comprises the steps
of cold gas-dynamic spraying a powder material on the metal component
surface to form a coating, the powder material being sufficiently heated
to impact the metal component surface at between about 30% and about 70%
of the powder material's melting temperature in kelvins. Another method
for coating a surface of a metal component using a powder material
comprises the steps of heating the metal component surface to between
about 30% and about 70% of the substrate's melting temperature, and then
of the powder material's melting temperature in kelvins, and cold
gas-dynamic spraying the powder material on the metal component surface
to form a coating. |
|
Margaret M Floyd |
|
Timothy R Duffy |
|
20060272909 |
Jun. 2, 2005 |
Delphi Technologies, Inc |
BRAKE ASSEMBLY AND COATING |
|
DOW |
