EP3431630A1 - Wasserstoffbasierte kaltsprühdüse und verfahren - Google Patents

Wasserstoffbasierte kaltsprühdüse und verfahren Download PDF

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Publication number
EP3431630A1
EP3431630A1 EP18184451.5A EP18184451A EP3431630A1 EP 3431630 A1 EP3431630 A1 EP 3431630A1 EP 18184451 A EP18184451 A EP 18184451A EP 3431630 A1 EP3431630 A1 EP 3431630A1
Authority
EP
European Patent Office
Prior art keywords
gas
stream
accelerant
hydrogen
nozzle
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP18184451.5A
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English (en)
French (fr)
Inventor
Lawrence Binek
Aaron T. Nardi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Raytheon Technologies Corp
Original Assignee
United Technologies Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by United Technologies Corp filed Critical United Technologies Corp
Publication of EP3431630A1 publication Critical patent/EP3431630A1/de
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles

Definitions

  • the present disclosure relates to a cold spray process which involves deposition of powdered materials through a supersonic nozzle using kinetic energy and plastic deformation upon impacting a target to consolidate the powdered materials. This occurs through a process similar to cold welding, where surface strains on the particle and the impacting substrate expose fresh metal surfaces which then bond.
  • helium is an expensive consumable without a reclamation system.
  • the helium gas temperature may need to be raised, increasing the sonic velocity of the gas, in turn increasing the particle impact velocity to a level which would then be sufficient to achieve good particle bonding. This increased heat can cause fouling of the nozzle, leading to a need to replace or maintain the nozzles to bring them back into service.
  • nitrogen can be used in the cold spray process for accelerating particles to sufficient velocities to achieve bonding.
  • the sonic velocity of nitrogen at any temperature is less than half of the velocity of helium at the same spray gas temperature.
  • increased temperature can increase the sonic velocity of nitrogen, but very high temperatures, 600-1000°C, may be required for many materials to achieve acceptable velocity at which point many of the attractive characteristics of a cold spray deposit are lost.
  • higher temperature helium it is also more likely to foul nozzles when running very high nitrogen temperatures.
  • a method for cold spray deposition of a material on a substrate comprising the steps of: entraining a metal powder material in a stream of accelerant gas comprising hydrogen; forming a flow of shield gas around the stream of accelerant gas; and impacting the substrate with the stream of accelerant gas whereby the metal powder material is deposited on the substrate.
  • the stream of accelerant gas comprises a majority of hydrogen.
  • the stream of accelerant gas comprises at least 70% vol hydrogen.
  • the stream of accelerant gas comprises at least 90% vol hydrogen.
  • the stream of accelerant gas has a critical velocity ratio of at least one.
  • the stream of accelerant gas has a critical velocity ratio of between 1.5 and 2.0.
  • the stream of accelerant gas is at a temperature of less than about 400°C.
  • the stream of accelerant gas is at a temperature of less than about 200°C.
  • gas mixture leaving an area of impact of the stream of accelerant gas with the substrate has a hydrogen content of less than 5% vol.
  • the shield gas is selected from the group consisting of inert gases and gas which is substantially inert with the substrate and metal powder at temperature of the stream of accelerant gas, and mixtures thereof.
  • the shield gas is selected from the group consisting of nitrogen, helium, argon, carbon dioxide and mixtures thereof.
  • the shield gas is nitrogen.
  • the metal powder material comprises particles of aluminum, copper, nickel, iron, tantalum, niobium, cobalt, or mixtures or alloys thereof, where the particle sizes vary from about 5 ⁇ m to 40 ⁇ m.
  • the metal powder material comprises particles of aluminum, copper or mixtures thereof.
  • the metal powder material comprises particles of aluminum having a particle size of between 20 and 40 ⁇ m.
  • the metal powder material comprises particles of copper having a particle size of between 10 and 30 ⁇ m.
  • the stream of accelerant gas is passed through a nozzle before the impacting step.
  • the flow of shield gas is at a higher pressure than the stream of accelerant gas.
  • the disclosure also provides an apparatus for cold spray deposition of a material on a substrate comprising: a nozzle communicated with accelerant gas and metal powder to be deposited on the substrate; a sleeve surrounding the nozzle and defining an annular space around the nozzle, the annular space being communicated with a shield gas.
  • the nozzle is defined substantially concentric within the sleeve.
  • the nozzle and the sleeve define an outlet for a centered stream of the accelerant gas and a cylinder of shield gas surrounding the centered stream.
  • a perforated bulkhead is provided in the annular space to adjust flow characteristics of the shield gas.
  • the present disclosure relates to cold spray deposition of a material such as a metal powder or particulate on a substrate.
  • FIG. 1 shows a prior art system 10 which uses helium as an accelerant gas.
  • System 10 includes a gas/heater control console 12, a powder feeder 14, a gas heater 16, a cold spray nozzle 18 and a spray hood 20.
  • the workpiece to be treated is treated in spray hood 20.
  • the first stream 22 passes through powder feeder 14 and conveys a helium with powder mixture to nozzle 18 at a relatively low flow rate.
  • the second stream 24 passes through gas heater 16 at a significantly higher flow rate, and is mixed with the first stream in nozzle 18 to deliver the powder entrained in helium accelerant gas at an elevated temperature and velocity.
  • the temperature can be increased but is limited to a point where the nozzle will be fouled. Further, if helium is used, the expensive gas is either lost, or must be recycled using expensive equipment.
  • FIG. 2 shows an illustrative embodiment of a system 50 using hydrogen.
  • System 50 includes a gas control console 52, a hydrogen source 54, a powder feeder 56 and a coaxial cold spray nozzle assembly 58 for applying powder to a substrate in spray hood 60.
  • Nozzle assembly 58 is also communicated with a source of shield gas, in this case nitrogen which is fed to nozzle assembly 58 through line 61.
  • Powder feeder 56, nozzle assembly 58 and spray hood 60 can be positioned within a cold spray acoustic enclosure 62 as illustrated.
  • a hydrogen detector 64 can be positioned in proximity to spray hood 60 to monitor for escaping hydrogen.
  • Enclosure 62 is also communicated with a source 66 of outside makeup air, and a dust collector 68 is also communicated with spray hood 60.
  • hydrogen is fed through one line 63 which passes through powder feeder 56 to deliver a stream of hydrogen and entrained powder particles to nozzle 58.
  • Shield gas is fed through stream 61, also to nozzle assembly 58.
  • Nozzle assembly 58 delivers a centered stream of hydrogen accelerant gas with entrained powder for cold spray deposition upon a workpiece, as well as a cylindrical flow of shield gas, in this case, nitrogen, surrounding the flow of hydrogen.
  • the shield gas serves to dilute and safely remove hydrogen gas from the point of application, after impact with the workpiece. This prevents escape of hydrogen at elevated levels or concentrations and helps ensure safety of the process.
  • Shield gas can be fed through line 61 at a significantly higher flow rate or pressure than the hydrogen accelerant gas.
  • high quality cold spray deposition can be accomplished at significantly lower temperatures which avoid fouling of the nozzle.
  • costs of heating of the accelerant gas can be avoided.
  • hydrogen is available at a reduced cost as compared to helium.
  • a system as shown in FIG. 2 can be used to produce high quality cold spray deposition using a cheaper accelerant gas and at conditions which produce higher quality deposition with less chance of fouling of the nozzle.
  • FIG. 3 shows a further illustrative embodiment according to the disclosure. Similar elements with respect to FIG. 2 carry similar reference numerals.
  • system 50' of FIG. 3 can be provided with a heater 70 to heat the stream of hydrogen, accelerant gas and powder, if desired. Due to the high velocity which can be accomplished using hydrogen as accelerant gas, any heating which will be necessary would be a low level of heating.
  • the heater 70 as shown in FIG. 3 could be a heating coil positioned within a box or tube-type furnace. Such a configuration is shown in FIG. 4 .
  • FIG. 4 shows heater 70 having a hydrogen gas tube 72 which passes through a box or tube furnace 74.
  • the tube 72 can be in the form of a coil within box 74, and can be surrounded by a conduit 76 for carrying shield or inert gas such as nitrogen.
  • pressure of shield gas in line 76 should be greater than pressure of hydrogen gas in line 72 so that any leaks do not result in loss of hydrogen into the work area or atmosphere.
  • FIG. 5 schematically illustrates flow in accordance with the present disclosure.
  • FIG. 5 shows workpiece 100 and schematically illustrates the outlet end 102 of a cold spray nozzle assembly 58.
  • a centrally located stream of accelerant gas 104 is impinged upon workpiece 100 from the nozzle of cold spray assembly 58, while a cylindrical shield of gas 106 is formed around the centered stream through shield gas flowing along an annular space 108 between nozzle 110 and outer sleeve 112.
  • Stream 104 engaging workpiece 100 remains substantially entirely hydrogen with entrained particles.
  • shield gas 106 which prevents the escape of undiluted hydrogen defines a cylindrical shield or shroud around the stream of accelerant gas.
  • arrows 114 schematically illustrate gases leaving the impact area, and these gases are diluted to the point where they contain hydrogen in an amount of up to about 5% vol.
  • exit velocity is a key parameter in obtaining good results with a cold spray deposition.
  • Table 1 Velocity performance of copper under various process conditions Gas Type Pressure (bar) Temperature (°c) Exit Velocity (m/s) He 30 20 674 N2 30 20 397 N2 30 1000 683 N2 60 600 666 H2 30 20 802
  • the flow of hydrogen accelerant gas can advantageously comprise a majority of hydrogen. More ideally, the accelerant gas can comprise at least 70% volume of hydrogen, more preferably at least 90% of volume hydrogen.
  • the stream of accelerant gas can advantageously be fed to the workpiece at a critical velocity ratio, or CVR (the ratio of particle velocity to the critical velocity for particle bonding), of at least one, and more desirably at a critical velocity ratio of between 1.5 and 2.0.
  • CVRs can be achieved at a temperature of the stream of accelerant gas of about 20°C when spraying copper particles with an average particle size of 20 ⁇ m and a gas pressure of 20 bar (2 MPa).
  • relatively high strength aluminum alloy powder such as aluminum alloy 6061, with an average particle size of about 30 pm, can achieve this same CVR range with a hydrogen gas temperature of only 100°C and a pressure of 20 bar (2 MPa).
  • the shield gas can advantageously be any gas which remains substantially inert at conditions likely to be encountered during the process. More specifically, the shield gas can be selected from the group consisting of inert gases and gases which are substantially inert with the substrate and metal powder at temperatures of the stream of accelerant gas and mixtures thereof. In a further non-limiting aspect of the disclosure, the shield gas can be selected from the group of nitrogen, argon, carbon dioxide, and mixtures thereof, most preferably nitrogen.
  • the substrate and powder materials can be any metals or ceramic-metal composites including aluminum, copper, nickel, iron, tantalum, niobium, cobalt or mixtures or alloys thereof.
  • the particles when the particles are aluminum, the particles desirably have a particle size of between 20 and 40 ⁇ m.
  • the metal powder material is particles of copper, these particles can be provided at a particle size of between 10 and 30 ⁇ m. Other desirable particle size ranges would be applicable to other metals and alloys where generally higher density and higher strength materials require lower particle size ranges.
  • FIG. 6 shows a cold spray nozzle assembly 58 according to the present disclosure mounted to a robot arm 200 which can be utilized and controlled to position nozzle 58 relative to 100.
  • FIG. 7 is an enlarged view of the nozzle portion of FIG. 6 , and shows nozzle assembly 58 with a split clamp 202 for mounting nozzle assembly 58 to arm 200.
  • Inlets 204, 206 lead through split clamp 202 and can be used to feed accelerant gas and powder to nozzle assembly 58 described above. This leads to a stream of accelerant gas and powder which exits nozzle assembly 58 at an outlet end 208 to impact workpiece 100.
  • An inlet 210 is shown which can be used to feed shield gas into a space between an outer sleeve 212 and the inner nozzle structure 214.
  • FIG. 8 is a perspective view similar to that shown in FIG. 7 , and further illustrates an annular space 216 through which shield gas flows during operation of the device.
  • FIG. 9 a sectional view of the nozzle assembly 58 as shown in FIG. 8 is presented, and further illustrates internal structure and gas flow of the apparatus according to this structure.
  • Inlets 204, 206 are shown through which powder feed and hydrogen gas feed can be conducted into a central flow area 218 which leads into the nozzle jet of nozzle 214 to produce a stream 104 of hydrogen accelerant gas with entrained powder particles for impacting workpiece 100 as desired.
  • FIG. 9 shows two inlets 210 through which shield gas are introduced into an annular space 216 between sleeve 212 and nozzle 214.
  • a bulkhead 217 can be positioned within annular space and have through-passages or perforations to allow shield gas to pass through bulkhead 217.
  • Such a configuration can help to produce a smooth and uniform flow of shield gas in a cylindrical pattern as desired.
  • FIG. 10 shows a side view of a further configuration of a hydrogen cold spray nozzle assembly.
  • like numerals have again been used to depict like elements.
  • One particular aspect of FIG. 10 is that a single inlet 205 is utilized for both hydrogen gas and powder. Since hydrogen can be used at relatively low or cool temperatures, the entire flow of hydrogen gas can be used to entrain the metal powders, and the entire flow can be substantially straight and aligned along the longitudinal access of stream 218 through nozzle 214. This simplifies construction of the device by removing one inlet, and is also advantageous in that the flow path of hydrogen is maintained in a straight line, therefore avoiding impact areas which could lead to fouling of the nozzle.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
EP18184451.5A 2017-07-19 2018-07-19 Wasserstoffbasierte kaltsprühdüse und verfahren Withdrawn EP3431630A1 (de)

Applications Claiming Priority (1)

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US15/653,582 US20190024242A1 (en) 2017-07-19 2017-07-19 Hydrogen based cold spray nozzle and method

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EP3431630A1 true EP3431630A1 (de) 2019-01-23

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11662300B2 (en) 2019-09-19 2023-05-30 Westinghouse Electric Company Llc Apparatus for performing in-situ adhesion test of cold spray deposits and method of employing
US11898986B2 (en) 2012-10-10 2024-02-13 Westinghouse Electric Company Llc Systems and methods for steam generator tube analysis for detection of tube degradation
US11935662B2 (en) 2019-07-02 2024-03-19 Westinghouse Electric Company Llc Elongate SiC fuel elements

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002085532A1 (en) * 2001-04-24 2002-10-31 Innovative Technology, Inc. A apparatus and process for solid-state deposition and consolidation of high velocity powder particles using thermal plastic deformation

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9168546B2 (en) * 2008-12-12 2015-10-27 National Research Council Of Canada Cold gas dynamic spray apparatus, system and method
US10590542B2 (en) * 2014-01-17 2020-03-17 Iones Co., Ltd. Method for forming coating having composite coating particle size and coating formed thereby
CA3003981C (en) * 2015-11-04 2023-08-29 Tessonics, Inc. Apparatus and method for cold spraying and coating processing

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002085532A1 (en) * 2001-04-24 2002-10-31 Innovative Technology, Inc. A apparatus and process for solid-state deposition and consolidation of high velocity powder particles using thermal plastic deformation

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11898986B2 (en) 2012-10-10 2024-02-13 Westinghouse Electric Company Llc Systems and methods for steam generator tube analysis for detection of tube degradation
US11935662B2 (en) 2019-07-02 2024-03-19 Westinghouse Electric Company Llc Elongate SiC fuel elements
US11662300B2 (en) 2019-09-19 2023-05-30 Westinghouse Electric Company Llc Apparatus for performing in-situ adhesion test of cold spray deposits and method of employing

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