PATENTS

        The following table contains a list of patents issued in the United States that make reference to the Cold Spray process. We have made every effort to update this resource with all relevant patents, however the very nature of the patent process may result in patents being classified under synonymous terms and therefore being missed in our searches. We ask for your help in identifying any patents that may have been missed and we will update this resource to provide a valuable tool for everyone working in the Cold Spray field. The complete abstracts, list of inventors and the assignees can be searched using the search function in your Web Browser. A .pdf copy of each patent can be downloaded directly from this website.

Current as of (September 29, 2008)
Patent No. Filed Assignee/Inventors Title/Abstract
706701 Mar. 23, 1900   METHOD OF IMPACTING ONE METAL UPON ANOTHER
DOWNLOAD Samuel H. Thurston  
1128059 Aug. 7, 1911 Metals Coating Company of America METHOD OF PLATING OR COATING WITH METALLIC COATINGS
DOWNLOAD Max U. Schoop  
3100724 Sep. 22, 1958 Microseal Products, Inc. DEVICE FOR TREATING THE SURFACE OF A WORKPIECE
DOWNLOAD Charles F. Rocheville  
7402277 Feb. 7, 2006 ExxonMobil Research and Engineering Company METHOD OF FORMING METAL FOAMS BY COLD SPRAY TECHNIQUE
DOWNLOAD Raghavan Ayer The present invention relates to a method of forming metallic foams using cold spray processing. The method allows for the formation of metallic foams on existing substrates as a layer. The method includes the steps of providing a substrate for coating of a metallic foam; cold spraying a mixture of metal particles and a foaming agent onto the substrate to form a substrate coated with an unexpanded metallic layer; foam heat treating the substrate coated with an unexpanded metallic layer at a temperature above the decomposition temperature of the foaming agent for a time sufficient to form a heated substrate coated with an expanded metal foam layer; and cooling the heated substrate coated with an expanded metal foam layer to about ambient temperature to form a cooled substrate coated with an expanded metal foam layer. The method of forming metallic foams on substrates finds application in the oil, gas, and chemical industry by being an integral part of casings, pipelines, transfer lines, and other flow lines.
Norman Pokutylowicz
5,302,414 19-May-90 Anatoly Nikiforovich Papyrin GAS-DYNAMIC SPRAYING METHOD FOR APPLYING A COATING
DOWNLOAD Anatoly P. Alkhimov A cold gas-dynamic spraying method for applying a coating to an article introduces into a gas particles of a powder of a metal, alloy, polymer or mechanical mixture of a metal and an alloy, the particles having a particular size of from about 1 to about 50 microns. The gas and particles are formed into a supersonic jet having a temperature considerably below a fusing temperature of the powder material and a velocity of from about 300 to about 1,200 m/sec. The jet is directed against an article of a metal, alloy or dielectric, thereby coating the article with the particles.
Anatoly N. Papyrin
Vladimir F. Kosarev
Nikolai I. Nesterovich
Mikahil M. Shushpanov
4,815,414 Apr. 20, 1987 Nylok Fastener Corporation POWDER SPRAY APPARATUS
DOWNLOAD Richard Duffy A method and apparatus for spraying powder material from a plurality of nozzles. A powder material feed control section and a manifold section provide a uniform flow rate and uniform density pattern for a powder material feed stream sprayed from a plurality of nozzles.
Eugene Sessa
5,795,626 Sep. 25, 1996 Innovative Technology Inc. COATING OR ABLATION APPLICATOR WITH A DEBRIS RECOVERY ATTACHMENT
DOWNLOAD Howard Gabel An environmentally compliant triboelectric applicator and process for coating or ablating a substrate and for retrieving excess or ejected material from the substrate. The applicator comprises an inner supersonic nozzle for accelerating tri-boelectrically charged projectile particles entrained in a supersonic gas to speeds sufficiently high to coat or ablate a substrate and an outer evacuator nozzle coaxially surrounding the inner supersonic nozzle for retrieving excess projectile particles. ablated substrate powders. or other environmentally hazardous materials. A fluid dynamic coupling uses the efficacy of the Mach turning angle associated with a supersonic boundary layer of carrier gas to aspirate the central core of the supersonic two-phase jet. This fluid coupling and spacing between the outlet of the supersonic nozzle and the substrate also permits the projectile particles and substrate to triboelectrically charge to levels which induce electrostatic discharges at the substrate simultaneous to the impacts. 
Ralph M. Tapphorn
6,015,586 Feb. 19, 1998 Acheson Industries, Inc. COLD DRY PLATING PROCESS FOR FORMING A POLYCRYSTALLINE STRUCTURE FILM OF ZINC-IRON BY MECHANICAL PROJECTION OF A COMPOSITE MATERIAL
DOWNLOAD Shigeru Omori High efficiency cold dry plating method for forming an important and highly adherent polycrystalline structured zinc alloy film on metallic substrates by mechanical projection of a composite material. High efficiency cold dry plating method using a composite material described as iron nuclei particles encapsulated by zinc alloy, where the composite material contains 45 to 80% of zinc. Cold dry plating process giving improved yield and short treatment time with high amount of zinc strongly adherent on metallic surfaces.
Jean Marie Kieffer
6,038,900 26-May-99 Fuji Kihan Co. Ltd. METHOD FOR A SURFACE TREATMENT OF METALLIC PRODUCT
DOWNLOAD Yoshio Miyasaka The present invention relates to a method for a surface treatment of a metallic product. In this method, by conducting one step of injecting mixture shots including at least two types of shots comprised of different or same materials consisting of high hardness metal or metallic component and having different shot diameters between 0.6 and 0.03 mm onto the surface of a metallic product at an injection pressure of not less than 0.29 MPa or not less than 50 mlsec, the residual comaressive stress of the surface of the metallic product and that of a lower surface layer are made at least -1200 MPa and that of a portion having a depth of about 50 pm below the surface of the metallic product is made -1300 MPa or higher.
6,074,135 Aug. 7, 1998 Innovative Technology Inc. COATING OR ABLATION APPLICATOR WITH DEBRIS RECOVERY ATTACHMENT
DOWNLOAD Howard Gabel An environmentally compliant triboelectric applicator and process for coating or ablating a substrate and for retrieving excess or ejected material from the substrate. The applicator comprises an inner supersonic nozzle for accelerating tri-boelectrically charged projectile particles entrained in a supersonic gas to speeds sufficiently high to coat or ablate a substrate. The applicator further comprises an outer evacuator nozzle coaxially surrounding the inner supersonic nozzle for retrieving excess projectile particles, ablated substrate powders, or other environmentally hazardous materials. A fluid dynamic coupling uses the eficacy of the Mach turning angle associated with a supersonic boundary layer of carrier gas to aspirate the central core of the supersonic two-phase jet. This fluid coupling and spacing between the outlet of the supersonic nozzle and the substrate also permits the substrate to triboelectrically charge to levels which induce electrostatic discharges at the substrate simultaneous to the impacts. The aspiration feature reduces the outlet pressure in the central core of the nozzle below ambient pressure which allows the projectiles to travel unimpeded to the substrate, and reduces the inlet pressure required to achieve parallel and shock-free flow with the inner supersonic nozzle. The powders are injected into the carrier gas using powder feeders modified for high pressure and the ablated debris with excess projectile particles are collected in a particle precipitator and filter unit using a suction blower. A special nozzle applicator embodiment and process for coating or ablating the internal surface of a cylinder bore is also disclosed. This nozzle applicator comprises an axisymmetric cylindrical nozzle for conveying, accelerating, and triboelectrically charging projectile particles entrained in a carrier gas to speeds sufficiently high to coat or ablate the internal surface of the cylinder bore substrate when impacted by a triboelectrically charged jet comprising a central core. 
Ralph M. Tapphorn
6,129,948 Dec. 22, 1997 National Center for Manufacturing Sciences SURFACE MODIFICATION TO ACHIEVE IMPROVED ELECTRICAL CONDUCTIVITY
DOWNLOAD Robert C. McCune A high-velocity spray nozzle is used to physically embed conductive particles into the surface of a non-conductive substrate, thereby rendering it electriclly conductive.  In contrast to existing, chemically based alternatives, the method offers the use of a dry process with no chemical baths and associated environmental concerns; the ability to produce localized modifications, only in areas where actually required; the use of simple materials, such as air and powdered graphite; and a potential cost savings.  Methods of modifying localized areas of the underlying substrate are also disclosed. 
Jeffrey H. Helms
Howard K. Plummer
6,139,913 Oct. 31, 2000 National Center for Manufacturing Sciences KINETIC SPRAY COATING METHOD AND APPARATUS
DOWNLOAD Thomas H. Van Steenkiste A method and apparatus is disclosed for kinetic spray coating of substrate surfaces by impingement of air or gas entrained powders of small particles in a range up to at least 106 microns accelerated to supersonic velocity in a spray nozzle. Preferably powders of metals, alloys, polymers and mixtures thereof or with semiconductors or ceramics are entrained in unheated air and passed through an injection tube into a larger flow of heated air for mixing and acceleration through a supersonic nozzle for coating of an article by impingement of the yieldable particles. A preferred apparatus includes a high pressure air supply carrying entrained particles exceeding 50 microns through an injection tube into heated air in a mixing chamber for mixing and acceleration in the nozzle. The mixing chamber is supplied with high pressure heated air through a main air passage having an area ratio relative to the injection tube of at least 80/1.
John R. Smith
Richard E. Teets
Jerome J. Moleski
Daniel W. Gorkiewicz
6,156,377 Jan. 7, 1999 Fuji Kihan Co. Ltd. CERAMIC DISPERSION PLATING PROCESS
DOWNLOAD Yoshio Miyasaka Provided is a low-priced metal coating treatment which causes less pollution, wherein the dispersion of ceramics and the foming of a metal coat are performed by blasting treatment; and a ceramic dispersion plating process making it possible to improve wear resistance, heat resistance and the like of a workpiece and the adhesion of the metal coat.  When ceramic particles are ejected on the surface of a workpiece comprising a metal or a metal component by blasting, the workpiece is heated and softened so that the ceramic particles are dispersed inside the workpiece to form a dispersed layer.  When a coating metal powder is further ejected thereon by blasting, the temperature of the dispersed layer rises in the same way so that elements in the composition of the coating metal powder diffuse and penetrate inside/on the surface of the dispersed layer to form a plating layer.
6,189,663 Jun. 8, 1998 General Motors Corporation SPRAY COATINGS FOR SUSPENSION DAMPER RODS
DOWNLOAD Wen-Jin Meng Electroplated chromium coatings on automobile suspension damper piston rods are replaced with thermal or kinetic spray coatings of: (a) suitable corrosion-resistant metal alloys such as iron and chromium containing nickel-based alloys or chromium containing steel, or (b) suitable ceramic coatings such as electrically insulative alumina ceramics.  The spray coatings are porous, and the metal alloy coatings usually should be sealed for corrosion protection.
Thomas H. Van Steenkiste
John Robert Smith
6,258,402 B1 Oct. 12, 1999   METHOD FOR REPAIRING SPRAY-FORMED STEEL TOOLING
DOWNLOAD Paul Earl Pergande A machine tool or die is fabricated from thermally spray-formed steel is easily repaired by cleaning, roughing and covering the surface to be repaired by a cold-spray layer of metal and then forming a weldment by conventional electric welding processes.  The repaired surface is then finished by conventional machining, grinding and polishing and then the tool is put back into service.
Robert Corbly McCune
Nakhleh Hussary
6,258,417 B1 Mar. 26, 1999 Research Foundation of State University of New York METHOD OF PRODUCING NANOCOMPOSITE COATINGS
DOWNLOAD Sanjay Sampath 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 nanocystalline, high pressure phase.
Herbert Herman
John Parise
Ramasis Goswami
6,283,386 B1 23-May-00 National Center for Manufacturing Sciences, Ann Arbor, Mich (US) KINETIC SPRAY COATING APPARATUS
DOWNLOAD John R. Smith  An apparatus is disclosed for kinetic spray coating of substrate surfaces by impingement of air or gas entrained powders of small particles in a range up to at least 106 microns accelerated to supersonic velocity in a spray nozzle.  Preferably powders of metals, alloys, polymers and mixtures thereof or with semiconductors or ceramics are entrained in unheated air and passed through an injection tube into a larger flow of heated air for mixing and acceleration through a supersonic nozzle for coating of an article by impingement of the yieldable particles.  A preferred apparatus includes a high pressure air supply carrying entrained particles exceeding 50 microns through an injection tube into heated air in a mixing chamber is supplied with high pressure heated air through a main air passage having an area ratio relative to the injection tube of at least 80/1.
Richard E. Teets
Daniel W. Gorkiewicz
Jerome J. Moleski
Thomas H. Van Steenkiste
6,291,012 B1 Feb. 3, 1998 Fuji Kihan Co. Ltd. METHOD FOR FORMING A METALLIC COAT BY IMPACTING METALLIC PARTICLS ON A WORKPIECE
DOWNLOAD Yoshio Miyasaka Method for forming metallic coat where, the surface of workpiece is partly covered with a masking material having a predetermined pattern, and metallic powders are ejected to the surface at the ejection velocity of 80 m/sec or higher or at the ejection pressure of 0.3 Mpa or higher by utilising an ejection apparatus such as blast work apparatus, in order to easily attain the metallic coat having high adhesion strength without washing process, nor heat process by a relatively simple facility.
6,315,188 B1 Jun. 28, 2000 Sandia Corporation SURFACE PREPERATION FOR HIGH PURITY ALUMINA CERAMICS ENABLING DIRECT BRAZING IN HYDROGEN ATMOSPHERES
DOWNLOAD Nancy Yuan Chi Yang  The present invention relates to a method for preparing the surface of a high purity alumina ceramic or sapphire specimen that enables direct brazing in a hydrogen or sapphire atmosphere using an active braze alloy.  The present invention also relates to a method for directly brazing a high purity alumina ceramic or sapphire specimen to a ceramic or metal member using this method of surface preparation, and to articles produced by this brazing method.  The presence of silicon, in the form of a SiP2-containing surface layer, can more than double the tensile bond strength in alumina ceramic joints brazed in a hydrogen atmosphere using an active Au-16Ni-0.75 Mo-1.75V filler metal.  A thin silicon coating applied by PVD processing can, after air firing, produce a semi-continuous coverage of the alumina surface with a Sio2 film.  Room temperature tensile strength was found to be proportinal to the fraction of air fired surface covered by silicon-containing films.  Similarly, the ratio of substrate fracture versus interface separation was also related to the amount of surface silicon present prior to brazing.  This process can replace the need to perform a "moly-manganese" metallization step.
Floyd M. Hosking
Charles H Cadden
6,317,913 B1 8-May-00 Alcoa Inc. METHOD OF DEPOSITING FLUX OR FLUX AND METAL ONTO A METAL BRAZING SUBSTRATE
DOWNLOAD John B. Eye The present invention is directed to a means for the surface preparation of a metal or metal alloy substrate.  In the process of the present invention, a stream of a mixture of flux particles and metal particles is hurled at the substrate at velocities effective for flux adhesion to the surface.  The velocities of the particle stream is adjusted so that the flux particles adhere to the surface and the metal particles bounce off the surface.  At higher temperatures and velocities, the metal particles are co-deposited with the flux.
Raymond J. Kilmer
6,329,025 B1 Jun. 10, 1998 University of Texas System Board of Regents METHOD AND APPARATUS FOR ELECTROMAGNETIC POWDER DEPOSITION
DOWNLOAD Darwin G. Davis The present invention provides a method for depositing powder particles on a substrate.  The method comprises forming a planar plasma armature, accelerating the plasma armature, accelerating a column of gas with the plasma armature; and accelerating the powder particles with the column of gas.  The present invention provides for a railgun, comprinsing first and second conducting rails, and first and second insulating rails.  The insulating and conducting rails form a bore of the railgun.  The first and second conducting rails are separated by the insulating rails.  At least one of the rails has a port in the wall thereof, the port is adapted to introducing powder particles into the bore.
Robert L. Sledge 
Robert J. Polizzi
John R. Uglum, Jr.
Raymond C. Zowarka
William F. Weldon
James L. Bacon
6,344,237 B1 Mar. 3, 2000 Alcoa Inc. METHOD OF DEPOSITING FLUX OR FLUX AND METAL ONTO A METAL BRAZING SUBSTRATE
DOWNLOAD John B. Eye The present invention is directed to a means for the surface preparation of a metal or metal alloy substrate.  In the process of the present invention, a stream of a mixture of flux particles and metal particles is hurled at the substrate at velocities effective for flux adhesion to the surface.  The velocities of the particle stream is adjusted so that the flux particles adhere to the surface and the metal particles bounce off the surface.  At higher temperatures and velocities, the metal particles are co-deposited with the flux.
Raymond J. Kilmer
6,345,440 B1 Jul. 21, 2000 Ford Global Technologies Inc. METHODS FOR MANUFACTURING MULTI-LAYER ENGINE VAVLE GUIDES BY THERMAL SPRAY
DOWNLOAD Oludele Olusegun Popoola A method of making valve guides by thermal spraying a wear-resistant layer onto a rotating mandrel that is subsequently built up by thermal spraying steel on the wear-resistant layer.  A flame spray polymer lubricant may be applied to the wear-resistant layer to improve self-lubricating properties of the engine valve guide.  The mandrel and  applied layers are then cut off and the remaining segment is further processed in a machining operation to remove the mandrel from inside of the engine valve guide.  The mandrel is preferably cooled as the thermal spray is applied preferably by routing a cooling fluid such as air through the mandrel.
Robert Corbly McCume
Larry Van Reatherford
6,348,687 B1 Sep. 10, 1999 Sandia Corporation AERODYNAMIC BEAM GENERATOR FOR LARGE PARTICLES
DOWNLOAD John R. Torczynski A new type of aerodynamic particle beam generator is disclosed.  This generator produces a tightly focused beam of large material particles at velocities ranging from a few feet per second to supersonic speeds, depending on the exact configuration and operating conditions.  Such generators are of particular interest for use in additive fabrication techniques.
Ronald C. Dykhuizen
Richard A. Neiser
Mark F. Smith
John E. Brockmann
6,364,932 B1 2-May-00 The BOC Group COLD GAS-DYNAMIC SPRAYING PROCESS
DOWNLOAD Arthur I. Shirley The present invention provides an improved cold gasdynamic spraying process utilizing a carrier gas and smalldiameter particulates whereby the particulate-laden carrier gas is directed to a ceramic filter unit where the particulates arc scparatcd out and thc particulatc-frcc carricr gas is analyzed and returned to the spraying process or to other gas purification systems.
Michael Joseph McGowan
Daniel Arthur Morgan
Wenchang Ji, Doylestown
6,365,222 B1 Oct. 27, 2000 Siemens Westinghouse Power Corporation ABRADABLE COATING APPLIED WITH COLD SPRAY TECHNIQUE
DOWNLOAD David B. Allen A cold spray process (20) for applying an abradable coating (16) to a substrate material (12). A bond coat layer (14) andlor an abradable coating material layer (16) are applied to a substrate (12) by directing particles of the material toward the substrate surface at a velocity sufficiently high to cause the particles to deform and to adhere to the surface. Particles of the bond coat material may first be directed toward the substrate surface at a velocity sufficiently high to clean the surface (24) but not su£€iciently high to cause the particles to deform and to adhere to the surface.
Brij B. Seth
Gregg P. Wagner
6,402,050 B1 Oct. 27, 1997   APPARATUS FOR GAS-DYNAMIC COATING
DOWNLOAD Oleg Fedorovich Klyuev The apparatus is comprised of a compressed air source which is connected by a gas conduit to a heating unit whose outlet is connected to a supersonic nozzle inlet in which a supersonic portion is connected by a conduit to a powder feeder. Compressed air of presslire Po from the compressed air source by the gas conduit is delivered to the heating unit to be heated to the required temperature. The heated air enters the supersonic nozzle in which it is accelerated to a speed of several hundred meters per second. The powdered material is passed from the powder feeder by the powder feeding conduit to the supersonic nozzle portion in which it is accelerated by the air flow at section of the nozzle from the injection point to the nozzle outlet.
Timur Valerievich Buzdygar
Alexandr Ivanovich Kashirin
6,408,928 B1 Sep. 8, 2000 Linde Gas Aktiengesellschaft PRODUCTION OF FOAMABLE METAL COMPACTS AND METAL FOAMS
DOWNLOAD Heinrich Kreye A compact body is made by thermal spraying by highvelocity flame spraying or by cold-gas spraying. By heating the compact body to a temperature equal to or preferably above the breakdown temperature of the blowing agent, followed by cooling, porous hollow bodies or metal foams are produced.
Peter Heinrich, Germering
6,419,593 B1 Dec. 22, 1998 Linde Technische Gase GmbH GOLF CLUB HAVING A THERMIC-SPRAY COATING
DOWNLOAD Heinrich Kreye The invention relates to a golf club with a striking surface for striking golf balls. The golf club has a coating applied by a thermal spray method at least in the area of the striking surface. The club coatings are preferably applied by a high-speed flame spray method or by a cold gas spray method. For coating golf clubs by hot spraying, in particular metals, metal alloys, oxides, (especially N,0, andlor TiO,), carbides, borides, plastics, or mixtures of the above substances can be used as the spray materials.
Peter Heinrich, Germering
6,443,179 B1 Feb. 21, 2001 Sandia Corporation PACKAGING OF ELECTRO-MICROFLUIDIC DEVICES
DOWNLOAD Paul C. Galambos A new architecture for packaging surface micromachined electro-microfluidic devices is presented. This architecture relies on two scales of packaging to bring fluid to the device scale (picoliters) from the macro-scale (microliters). The architecture emulates and utilizes electronics packaging technology. The larger package consists of a circuit board with embedded fluidic channels and standard fluidic connectors (e.g. Fluidic Printed Wiring Board). The embedded channels connect to the smaller package, an Electro- Microfluidic Dual-Inline-Package (EMDIP) that takes fluid to the microfluidic integrated circuit (MIC). The fluidic connection is made to the back of the MIC through Boschetched holes that take fluid to surface micromachined channels on the front of the MIC. Electrical connection is made to bond pads on the front of the MIC.
John A. Emerson
Kenneth A. Peterson
Rachel K. Giunta
Robert D. Watson
Gilbert L. Benavides
6,444,259 B1 Jan. 30, 2001 Siemens Westinghouse Power Corporation THERMAL BARRIER COATING APPLIED WITH COLD SPRAY TECHNIQUE
DOWNLOAD Gregg P. Wagner Aprocess (20) for applying a thermal barrier coating (51) to a turbine component (50) including the step (34) of depositing a bond coating layer (56) by, directing solid particles using a cold spray process. The layer of bond coating material may have different depths (80,82) in different areas of the component (SO), and it may have different compositions (60,62) across its depth. The precise control afforded by the cold spray material deposition step allows the surface of the bond coating material layer to be formed with a predetermined surface roughness or with a plurality of micro-ridges (86) in order to optimize its bond to the overlying ceramic insulating layer (52).
Brij B. Seth
Ramesh Subramanian
6,455,465 B1 Aug. 10, 1999 Fuji Kihan Co. Ltd. PHOTOCATALYST COATED PRODUCTS AND A METHOD FOR PRODUCING A PHOTOCATALY ST LAYER
DOWNLOAD Yoshio Miyasaka A photocatalyst coated product having excellent photocatalytic functions including a decomposing function and a hydrophilic function achieved by forming on the surface of a product to be treated a titania layer as a photocatalyst having high hardness and high adhesion with the product to be treated, using an easy blasting treatment. The photocatalyst coated product has a decomposing function including deodorizing, antibacterial and soil-resisting actions, and also a hydrophilic function, which is provided by having a titania layer formed on the surface of a product to be treated by injecting a titanium or titanium alloy-containing powder against the surface of the product to be treated which is a metal product, a ceramic or a mixture of them.
6,464,933 BI Jun. 29, 2000 Ford Global Technologies Inc. FORMING METAL FOAM STRUCTURES
DOWNLOAD Ray Jahn A method of fabricating a foamed metal structure using a powder supply of metal particles, comprising: (a) introducing the powder supply along with foaming agent particles into a propellant gas to form a gaslparticle mixture stream; (b) projecting the mixture stream at a critical velocity of at least sonic velocity onto a metallic substrate to create a deposit of pressure-welded metal particles containing the admixed foaming agent; and (c) subjecting at least the coating of the substrate to a thermal excursion effective to activate expansion of the foaming agent while softening the metal particles for plastic deformation under the influence of the expanding gases.
Robert Corbly McCune
Oludele Olusegun Popoola
6,465,039 BI Aug. 13, 2001 General Motors Corporation METHOD OF FORMING A MAGNETOSTRICTIVE COMPOSITE COATING
DOWNLOAD Delphi Technologies Inc.
Thomas H. Van Steenkiste A low porosity, strong, composite magnetostrictive coating is formed on a substrate by low temperature, high velocity spraying of a particulate mixture of a magnetostrictive REFe, composition and a strong metallic matrix material. The practice is particularly useful for forming circumferential bands of composite magnetostrictive material on a round shaft such as an automobile steering column. An example of a composite material is the magnetostrictive SmFe, compound and iron or copper as the strengthening matrix material.
Jerome Joseph Moleski
Martin Stephen Meyer
Frederick Eugene Pinkerton
6,491,208 B2 Dec. 5, 2000 Siemens Westinghouse Power Corporation COLD SPRAY REPAIR PROCESS
DOWNLOAD Greg P. Wagner A proccss (30) for thc rcpair of a componcnt 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
6,502,767 B2 2-May-01 ASB Industries ADVANCED COLD SPRAY SYSTEM
DOWNLOAD Jeganathan Karthikeyan 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 therefrom, a nozzle holder having a bore disposed therethrough 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. The nozzle having an initially converging, subsequently diverging centrally disposed bore therein adapted to receive the mixed powder and gas from the mixing chamber.
Albert Kay
6,517,791 BI Dec. 4, 2000 Praxair Technology Inc. SYSTEM AND PROCESS FOR GAS RECOVERY
DOWNLOAD Scot Eric Jaynes This invention is directed to a three-stage process for recovering and purifying a helium gas, and a system for using the three-stage process. The steps comprises a) introducing a gas from a cold spray forming chamber to a particulate removing apparatus to form a particulate-free helium gas, and recycling a first portion of the particulatefree helium gas back to the chamber; b) passing a second portion of the particulate-free helium gas to a first compressor prior to passing a helium gas purification membrane to form a purified helium gas and an exhaust gas, and passing the purified helium gas to mix with the first portion of particulate-free helium gas to the chamber; and c) passing a third portion of the particulate-free helium gas to a liquid separator apparatus to remove water and a receiver to dampen any pulsation to form a liquid-free helium gas, and recycling the liquid-free helium gas to said cold spray forming chamber.
6,528,123 B1 Jun. 28, 2000 Sandia Corporation COATING SYSTEM TO PERMIT DIRECT BRAZING OF CERAMICS
DOWNLOAD F. Michael Hosking This invention relates to a method for preparing the surface of a ceramic component that enables direct brazing using a non-active braze alloy. The present invention also relates to a method for directly brazing a ceramic component to a ceramic or metal member usin-g this method of surface preparation, and to articles produced by using this brazing method. The ceramic can be high purity alumina. The method comprises applying a first coating of a siliconbearing oxide material (e.g. silicon dioxide or mullite (3Al20,.2Si0,) to the ceramic. Next, a thin coating of active metal (e.g. Ti or V) is applied. Finally, a thicker coating of a non-active metal (e.g. Au or Cu) is applied. The coatings can be applied by physical vapor deposition (PVD). Alternatively, the active and non-active metals can be co-deposited (e.g. by sputtering a target made of mullite). After all of the coatings have been applied, the ceramic can be fired at a high temperature in a non-oxidizing environment to promote diffusion, and to enhance bonding of the coatings to the substrate. After firing, the metallized ceramic component can be brazed to other components using a conventional non-active braze alloy. Alternatively, the firing and brazing steps can be combined into a single step. This process can replace the need to perform a "molymanganese" metallization step.
Charles H. Cadden
6,541,883 B2 1-May-01 Walbro Corporation RFI SHIELD STRUCTURE FOR AN ELECTRIC MOTOR IN A FUEL PUMP HOUSING
DOWNLOAD Bradley L. Uffelman A shield structure for reducing radio frequency interference (RFI) from an electric motor situated within a fuel pump housing having an end with a fuel inlet and another end with a fuel outlet. The shield structure includes, first of all, an electrically insulative and hollow cup-like outer cover mountable on an end of the fuel pump housing adjacent the brushes and commutator of the electric motor. The outer cover has an inner surface, an outer surface, and preferably a fuel outlet opening defined therethrough. In addition, the shield stmcture includes an electrically conductive outer coat layer formed on substantially all of the outer surface of the outer cover. Lastly, the shield structure includes means for electrically grounding the outer coat layer to the electric motor of the fuel pump housing.
6,548,895 B1 Feb. 21, 2001 Sandia Corporation PACKAGING OF ELECTRO-MICROFLUIDIC DEVICES
DOWNLOAD Paul C. Galambos A new architecture for packaging surface micromachined electro-microfluidic devices is presented. This architecture relies on two scales of packaging to bring fluid to the device scale (picoliters) from the macro-scale (microliters). The architecture emulates and utilizes electronics packaging
John A. Emerson
Kenneth A. Peterson
Rachel K. Giunta
David Lee Zamora
Robert D. Watson
Gilbert L. Benavides
6,569,245 B2 Dec. 4, 2001 Rus Sonic Technology Inc. METHOD AND APPARATUS FOR APPLYING A POWDER COATING
DOWNLOAD Aley Galeevich Mukhamedzyanov The invention relates to the technology of applying a coating of powder materials by spraying and can be used for producing a coating of metals; their mechanical mixtures and dielectrics, adding various functional properties to treated surfaces. The proposed method of applying a powder coating comprised as follows: producing a gas-carrier flow, mixing powder with it, accelerating the gas-powder flow in the nozzle, generating its preset profile, further simultaneously generating the second gas-carrier flow, heating it, generating its preset profile and accelerating it in the nozzle, after that superimposing the accelerated gas-powder flow of the preset profile over the gas-carrier flow of the preset profile, and directing the cumulative jet to an article.
Vladislav Kuzmich Semenchenko
Valery Korneevich Krysa
6,576,861 B2 23-May-01 The Research Foundation of State University of New York METHOD AND APPARATUS FOR FINE FEATURE SPRAY DEPOSITION
DOWNLOAD Herbert Herman A system for fine feature spray deposition includes a substrate platform for supporting a substrate on which the features are to be deposited. A spray assembly is provided which includes a spray source for providing a stream of material to be deposited on a substrate, a collimator which is positioned in a path of the stream from said spray source and an aperture assembly, which is positioned downstream of the collimator with respect to the spray source and above the substrate platform. The aperture assembly defines at least one opening to pass a portion of the stream of material onto a surface of the substrate. A drive mechanism is provided which is coupled to at least one of the spray assembly and the substrate platform for inducing relative motion there between. A controller is coupled to the spray assembly and the drive mechanism to control the relative motion and the stream of material. The system allows fine features to be printed directly on a substrate with requiring a predefined mask. Multila~ers tructures, such as electrical components for circuits or sensor systems, can be formed by sequentially depositing features with various electrical properties.
Robert Greenlaw
Sanjay Sampath
6,592,935 B2 30-May-01 Ford Motor Company METHOD OF MANUFACTURING ELECTROMAGNETIC DEVICES USING KINETIC SPRAY
DOWNLOAD John Matthew 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 Corbly McCune
Franco Leonardi
6,592,947 B1 Apr. 12, 2002 Ford Global Technologies Inc. METHOD FOR SELECTIVE CONTROL OF CORROSION USING KINETIC SPRAYING
DOWNLOAD John Lawrence Bomback The present invention relates to methods for selectively enhancing corrosion protection of fabricated metal parts. One method of the present invention includes providing a non-galvanized metal sheet to be processed to form the fabricated metal part; selecting a localized region on the non-galvanized metal sheet; roughening the localized region for acceptance of a protective coating; applying a protective coating to localized region; and fabricating the nongalvanized metal sheet into a fabricated metal part. Another method includes providing a galvanized metal sheet; selecting a localized region on the galvanized metal sheet; applying a protective coating to the localized region; and fabricating the galvanized metal sheet into a fabricated metal part. Yet another method includes selecting a localized region on a fabricated metal part; roughening the localized region for acceptance of a protective coating; and applying the protective coating to the localized region.
Guilian Gao
Robert Corbly McCane
6,602,545 B1 Jul. 25, 2000 Ford Global Technologies Inc. METHOD OF DIRECTLY MAKING RAPID PROTOTYPE TOOLING HAVING FREE-FORM SHAPE
DOWNLOAD Furqan Z Shaikh A method and apparatus for directly making rapid prototype tooling from a computer model having a free-form shape. The method steps comprise essentially: (a) machining a soft metal tooling base so as to contour at least one free-form surface in conformity with the computer model; (b) cold-gas dynamic spraying the contoured surface to form superimposed impact welded metal particle layers, the layers consisting of at least one thermal management under-layer comprising primarily copper, and at least an outer wear resistant layer comprising primarily tool steel.
Howard Douglas Blair
Tsung-Yu Pan
6,620,645 B2 Nov. 16, 2001 G.T. Equipment Technologies Inc MAKING AND CONNECTING BUS BARS ON SOLAR CELLS
DOWNLOAD Yuepeng Wan A method for fabricating multi-cell solar devices using thermal spray deposition techniques to spray metal powder directly on solar cells and on the backing upon which solar cells are assembled, to form collection grid lines, bus bars, electrodes and interconnections between solar cells.
Alleppey V. Hariharan
Jonathan A. Talbott
Mohan Chandra
6,623,796 B1 Apr. 5, 2002 Delphi Technologies Inc. METHOD OF PRODUCING A COATING USING A KINETIC SPRAY PROCESS WITH LARGE PARTICLES AND NOZZLES FOR THE SAME
DOWNLOAD Thomas H. Van Steenkiste A method of depositing large particles having an average nominal diameter of greater than 106 microns 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.
6,627,814 B1 Mar. 22, 2002   HERMETICALLY SEALED MICRO-DEVICE PACKAGE WITH WINDOW
DOWNLOAD David H. Stark A method for manufacturing a cover assembly including a transparent window portion and a frame that can be joined to a micro-device package base to form a hermetically sealed micro-device package. First, a frame is provided having a continuous sidewall defining a frame aperture therethrough. The sidewall includes a frame seal-ring area circumscribing the frame aperture. The frame seal-ring area has a metallic surface. A sheet of a transparent material is provided having a window portion defined thereupon. The window portion has finished top and bottom surfaces. Next, a sheet seal-ring area on the sheet is prepared, the sheet seal-ring area circumscribing the window portion. Next, the prepared sheet seal-ring area of the sheet is metallized. Next, the frame is positioned against the sheet such that at least a portion of the frame seal-ring area and at least a portion of the sheet seal-ring area contact one another along a continuous junction region that circumscribes the window portion. Next, the junction region is heated until a metal-to-metal joint is formed between the frame and sheet all along the junction region, whereby a hermetic seal circumscribing the window portion is formed.
6,651,843 B2 Nov. 13, 2001 Flame-Spray Industries, Inc. METHOD AND APPARATUS FOR THE CONTROLLED SUPPLY OF FEEDSTOCK TO A FEEDSTOCK PROCESSING FACILITY OPERATING AT HIGH PRESSURE
DOWNLOAD Daniel R. Marantz A feedstock feeder for supplying feedstock to a system operating at a level of pressure. The feedstock feeder includes a pressure vessel having a pressure which is higher than the level of pressure; a mechanical feeder portion which meters the flow of feedstock to the system, the mechanical feeder portion located within the pressure vessel; a feedstock supplier which supplies feedstock to the mechanical feeder portion, the feedstock supplier located within the pressure vessel; a drive mechanism for driving a dynamically moving portion attached to the drive mechanism, the dynamically moving portion coupled to the mechanical feeder portion for moving the mechanical feeder portion; and wherein all dynamic seals operating to seal about the dynamically moving portion are positioned within the pressure vessel.
Keith A. Kowalsky
6,682,774 B2 Jun. 7, 2002 Delphi Technologies Inc. DIRECT APPLICATION OF CATALYSTS TO SUBSTRATES FOR TREATMENT OF THE ATMOSPHERE
DOWNLOAD Michel Farid Sultan A method for direct application of a catalyst to a substrate for treatment of atmospheric pollution including ozone. The method includes applying a catalytic metal to a substrate utilizing a kinetic spray process. The process can be utilized to apply a base metal such as copper to a substrate and the base metal becomes the catalytically active oxide following application to the substrate. This system replaces a rnultistep process with a single step process to provide a catalytically active surface that can be utilized to reduce ground level ozone and other atmospheric pollutants.
Ming-Cheng Wu
Zhibo Zhao
John R. Smith
6,685,988 B2 Oct. 9, 2001 Delphi Technologies Inc. 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 H. Van Steenkiste
6,689,453 B2 Apr. 1, 2002 Research Foundation of State University of New York ARTICLES WITH NANOCOMPOSITE COATINGS
DOWNLOAD Sanjay Sampath 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.
John Parise
Herbert Herman
Ramasis Goswami
6,706,319 B2 Jul. 26, 2002 Siemens Westinghouse Power Corporation MIXED POWDER DEPOSITION OF COMPONENTS FOR WEAR, EROSION AND ABRASION RESISTANT APPLICATIONS
DOWNLOAD Gregg P. Wagner An abrasive coating and a process for forming the abrasive coating by co-depositing hard particles within a matrix material onto a substrate using a cold spray process. The cold sprayed combination of hard particles and matrix material provides a coating that is wear, erosion and oxidation resistant. The abrasive coating may have different compositions across its depth. The hard particles may be deposited at different densities across the thickness of the matrix material. A first layer of the abrasive coating proximate the surface of the substrate may be devoid of hard particles.
Brij B. Seth
6,722,584 B2 Nov. 30, 2001 ASB Industries Inc. COLD SPRAY SYSTEM NOZZLE
DOWNLOAD Jeganathan Karthikeyan 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 therefrom, a nozzle holder having a bore disposed therethrough 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.
Albert Kay
6,723,379 B2 Apr. 26, 2002   HERMETICALLY SEALED MICRO-DEVICE PACKAGE USING COLD-GAS DYNAMIC SPRAY MATERIAL DEPOSITION
DOWNLOAD David H. Stark A method for manufacturing a cover assembly including a transparent window portion and a metallic frame that can be joined to a micro-device package base to form a hermetically sealed micro-device package. A sheet of a transparent material is provided having a window portion defined thereupon, the window portion having finished top and bottom surfaces. A frame-attachment area is prepared on the sheet, the frame-attachment area circumscribing the window
6,726,953 B2 Dec. 26, 2000 Sintobrator Ltd. METHOD FOR DEPOSITING METAL HAVING HIGH CORROSION RESISTANCE AND LOW CONTACT RESISTANCE AGAINST CARBON ON SEPARATOR FOR FUEL CELL
DOWNLOAD Nippon Steel Corporation
Hiroshi Kihira A method for depositing a metal having a high corrosion resistance and a low contact resistance against carbon to a separator for a fuel cell enabling provision of an inexpensive separator for a fuel cell by depositing a metal having a high corrosion resistance and a low contact resistance against carbon to the surface of a metal conveniently by simple equipment while using as a preform a metal such as stainless steel or aluminum as a material having a high productivity and low price and in addition capable of reducing the weight by making the sheet thickness thin, comprising projecting to a separator of a unit cell for forming the fuel cell a solid plating material comprised of core particles having a higher hardness than the separator and coated with a metal having a high corrosion resistance and a low contact resistance against carbon so as to compulsorily deposit the metal coated on this solid plating material to the separator.