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Pub. No. |
Filed |
Assignee/Inventors |
Title/Abstract |
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20010042508 |
May 2, 2001 |
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ADVANCED COLD SPRAY SYSTEM |
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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
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. |
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Jeganathan Karthikeyan |
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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 |
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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). |
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Brij B. Seth |
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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 |
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Tsung-Yu Pan |
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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 |
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Tatsuya Kato |
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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 |
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Franco Leonardi |
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20020182314 |
Jul. 29, 2002 |
Ford Motor Company |
METHOD OF MANUFACTURING ELECTRIC MACHINES USING KINETIC SPRAY |
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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 |
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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 |
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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 |
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Thomas Hubert Van Steenkiste |
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Yang Luo |
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Hartley F. Hutchins |
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Bryan A. Gillispie |
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20030077952 |
Oct. 9, 2001 |
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KINETIC SPRAYED ELECTRICAL CONTACTS ON CONDUCTIVE SUBSTRATES |
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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 |
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Bryan A. Gillispie |
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Thomas Hubert Van Steenkiste |
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20030175559 |
Mar. 15,2002 |
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KINETICALLY SPRAYED ALUMINUM METAL MATRIX COMPOSITES FOR THERMAL
MANAGEMENT |
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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 |
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Brian K. Fuller |
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Brvan A. Gillispie |
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Donald T. Morelli |
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Daniel W. Gorkiewicz |
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20030184976 |
Apr. 2,2002 |
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ELECTROMAGNETIC INTERFERENCE SHIELD FOR OVERMOLDED PACKAGING OF AN
ELECTRONIC ASSEMBLY |
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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 |
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Scott D. Brandenburg |
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20030190413 |
Apr. 5,2002 |
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METHOD OF MAINTAINING A NON-OBSTRUCTED INTERIOR OPENING IN KINETIC SPRAY
NOZZLES |
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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 |
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Alaa A. Elmoursi |
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Bryan A. Gillispie |
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Nilesh B. Patel |
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Thomas Hubert Van Steenkiste |
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20030190414 |
Apr. 5,2002 |
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LOW PRESSURE POWDER INJECTION METHOD AND SYSTEM FOR A KINETIC SPRAY
PROCESS |
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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. |
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20030190415 |
Apr. 5,2002 |
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METHOD OF PRODUCING A COATING USING A KINETIC SPRAY PROCESS WITH LARGE
PARTICLES AND NOZZLES FOR THE SAME |
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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. |
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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 |
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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 |
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Alexander V. Shkidkin |
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Oleg E. Kliouev |
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Timour V. Bouzdygar |
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Roman Gr. Maev |
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John M. Paille |
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Emil E. Strumban |
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20030219576 |
May 23,2002 |
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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 |
