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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. |
| | | | |