EP3526369B1 - Cold spray apparatus with large area conformal deposition ability - Google Patents

Cold spray apparatus with large area conformal deposition ability Download PDF

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Publication number
EP3526369B1
EP3526369B1 EP17862179.3A EP17862179A EP3526369B1 EP 3526369 B1 EP3526369 B1 EP 3526369B1 EP 17862179 A EP17862179 A EP 17862179A EP 3526369 B1 EP3526369 B1 EP 3526369B1
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EP
European Patent Office
Prior art keywords
nozzle
particles
cold spray
inner passage
spray apparatus
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EP17862179.3A
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German (de)
English (en)
French (fr)
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EP3526369A4 (en
EP3526369A1 (en
Inventor
Pravansu S. Mohanty
Vikram VARADARAAJAN
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University of Michigan
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University of Michigan
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Priority claimed from US15/295,050 external-priority patent/US10119195B2/en
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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
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • 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
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/082—Coating starting from inorganic powder by application of heat or pressure and heat without intermediate formation of a liquid in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
    • B05B7/1404—Arrangements for supplying particulate material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
    • B05B7/1481—Spray pistols or apparatus for discharging particulate material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • B05B7/228—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using electromagnetic radiation, e.g. laser
    • 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 an apparatus for applying a coating to a substrate and, more particularly, to a laser assisted cold spray apparatus for applying conformal coating to a large area.
  • Cold spraying is a type of additive process in which a stream of solid particles is accelerated to high speeds by a carrier gas through a nozzle toward a substrate.
  • the particles have enough kinetic energy such that upon impact with the substrate, they deform plastically and bond metallurgical-ly/mechanically to the substrate to form a coating.
  • metallurgical bonding is preferred, all the particles may not be necessarily bonded in a metallurgical fashion.
  • the particles are accelerated to a critical velocity such that the coating can be created.
  • This critical velocity can depend on the properties of the particles and to a lesser degree on the material of the substrate (i.e., deformability, shape, size, temperature, etc.).
  • the particles adhere to the substrate when their kinetic energy is converted to a sufficient level of thermal and strain (mechanical) energy leading to a phenomenon known in art as "adiabatic shear instability.” It has been observed that the deposition efficiency of a given material is increased as the temperature of the particles is increased up to a certain extent, which is typically achieved by increasing the carrier gas temperature.
  • the carrier gas temperature also influences the gas dynamics through the convergent-divergent nozzle that is typically used in a cold spray process. In other words, all things remaining constant, a higher carrier gas temperature leads to a higher gas velocity in the divergent section of the nozzle, which in turn may lead to higher particle velocity.
  • the cold spray nozzle is typically traversed on a substrate while maintaining a suitable target distance. This results in a coating along a small track (typically similar to the width of the nozzle exit) on the substrate.
  • a small track typically similar to the width of the nozzle exit
  • the nozzle is scanned on the substrate multiple times, typically in a raster pattern with the help of a motion system such as a robot.
  • the nozzle exit width is limited by the gas dynamics requirements for a given convergent-divergent nozzle, to achieve the desired particle velocity as well as the distribution.
  • the geometry of the convergent section, the divergent section as well as the throat connecting the two sections determine the gas flow behavior, which in turn influences the particle velocity and the particle distribution. It is not straight forward to just increase the nozzle cross section area to coat a larger substrate. For practical applications, it is recommended to optimize the geometry of the nozzle so that the necessary flow dynamics can be achieved with standard industrial equipment (gas supply, heater, powder feeder etc.) economically.
  • KR 2016 0080599 A discloses a cold spray apparatus according to the preamble of claim 1.
  • this application suffers from similar drawbacks.
  • WO 2011/069101 A2 a cold spray apparatus including a single nozzle is known. With such a design it is difficult to coat a substrate having an area larger than the nozzle exit width by scanning on the substrate multiple times, typically in a raster pattern with the help of a motion system such as a robot.
  • a cold spray apparatus for applying a coating of particles to a substrate, comprising a plurality of nozzles, including each nozzle defining an inner passage that terminates at a common exit for the entire assembly.
  • the nozzle assembly also includes a particle supply members in communication with the inner passages. The particle supply members supply the particles to flow and accelerate through the inner passages and out of the nozzle via the common nozzle exit toward the substrate to be coated thereon.
  • each nozzle includes a laser beam that is transmitted through the inner passage and exits via the common nozzle exit toward the substrate. The laser heats at least one of the particles within the inner passage and the substrate to promote coating of the substrate with the particles.
  • a method for enhancing the interaction of the particles with the laser beam within the inner passage of the nozzle, and thereby improving the energy absorption includes minimizing backward scattering of the laser beam by injecting particles in the divergent section of the nozzle, distributing the particles uniformly therein and hence increasing the interaction of the particles with the laser beam.
  • methods for integrating the particle stream from each nozzle into a common particle stream having substantially uniform particle distribution density and directing the combined stream with substantially uniform particle characteristics towards the substrate are provided to increase the deposition efficiency and uniformity. This optionally includes terminating each nozzle's inner passage at an optimal distance from the common exit of the apparatus assembly.
  • methods for coating complex substrates are provided. This optionally includes organizing a plurality of nozzles, having a predetermined common exit geometry that mimics the substrate geometric profile to be coated or built. Yet further, this also optionally includes supplying a desired amount of particles to each nozzle to achieve differential coating mass on the substrate, which in turn develops a desired geometric profile or conformality.
  • a cold spray nozzle assembly 10 is illustrated according to various exemplary embodiments of related U.S. Application No. 12/959,523.
  • the cold spray nozzle assembly 10 can be used for applying a coating of particles 17 to a substrate as will be described in greater detail below.
  • the assembly 10 can include a nozzle 5 having a substantially straight longitudinal axis X.
  • the nozzle 5 can define an inner passage 22 that extends parallel to the axis X.
  • the inner passage 22 can also include a nozzle entrance 22a and a nozzle exit 22c at opposite ends thereof ( FIG. 2 ).
  • the inner passage 22 can include a convergent section 21 adjacent the nozzle entrance 22a and a divergent section 23 adjacent the nozzle exit 22c. More specifically, both the convergent and divergent sections 21, 23 can be progressively tapered. The convergent section 21 narrows moving away from the entrance 22a, and the divergent section 23 widens moving toward the exit 22c.
  • the convergent section 21 is connected to the divergent section 23 to define a throat 22b ( FIG. 2 ).
  • the particles 17 flow through the inner passage 22, and the convergent and divergent sections 21, 23 ensure an appropriate flow field in the passage 22 such that the particles 17 move at a sufficient velocity to coat the substrate (not shown).
  • the nozzle 5 is substantially rectangular in shape. More specifically, the inner passage 22 ( FIG. 2 ) has a substantially rectangular cross section taken perpendicular to the axis X.
  • the entire inner passage 22 can have a similar substantially rectangular cross section along the entire axis X of the passage 22; however, it will be apparent that the area of such a cross section will change along the axis X due to the progressive tapering of the convergent and divergent sections 21, 23.
  • the inner passage 22 and the exit 22c can alternatively have any suitable non-circular shape, including square shape.
  • the nozzle 5 includes one or more particle supply inlets 13a, 13b.
  • the nozzle 5 can include any number of inlets 13a, 13b, and the inlets 13a, 13b are disposed in the divergent section 23 of the inner passage 22.
  • the particle supply inlets 28a, 28b ( FIG. 2 ) can each extend transverse to the axis X.
  • the particle supply inlets 28a, 28b can each be disposed at a positive acute angle relative to the axis X and generally toward the exit 22c.
  • the assembly 10 can include a particle supply member (not shown).
  • the particle supply member can be in (fluid) communication with the inner passage 22 of the nozzle 5 via the inlets 28a, 28b.
  • the particle supply member can include one or more tubes that are received in and operably coupled to the inlets 28a, 28b, respectively.
  • the particles 17 can be supplied from the supply member to flow through the inlets 28a, 28b, through the inner passage 22, and out of the nozzle exit 22c toward the substrate to coat it with the particles 17.
  • the assembly 10 includes a gas supply member 14.
  • the gas supply member 14 is in fluid communication with a gas source (not shown).
  • the gas source can supply any suitable gas to pressurize the inner passage 22 of the nozzle 5.
  • the assembly 10 includes a laser source 16.
  • the laser source 16 can be of any suitable type, such as a diode laser of a known type.
  • the laser source 16 can optionally include a fiber-optic cable 15 and at least one or more (e.g., three shown here) optical elements 25a, 25b, 25c ( FIG. 2 ).
  • the laser source 16 can be operably coupled to the first branch 18 of the pressure tube 11 so as to be substantially coaxial with the axis X.
  • the laser 16 emits a laser beam 29 ( FIG. 2 ) that is transmitted through the entrance 22a of the inner passage 22 of the nozzle 5 and out of the nozzle 5 via the exit 22c toward the substrate.
  • the laser beam 29 can be directed substantially parallel to and coaxial to the axis X toward the substrate, although some degree of spread of the beam 29 inward or away from the X axis may optionally be preferred.
  • the laser beam 29 heats particles below the particles' melting point. In some embodiments, laser beam 29 can heat particles below the particles' melting point only in and downstream of the divergent sections 23.
  • the assembly 10 can further include a handling device as well as process controller (not shown).
  • the handling device can be of any suitable type, such as a robotic handling device.
  • the controller can be of any suitable type, such as a programmable computer.
  • the controller can be in communication with the laser source, the handling device, the gas supply source, and the particle supply source for operating each.
  • the controller can also optionally be in communication with the pressure tube 11 for receiving feedback regarding the pressure and temperature inside the pressure tube 11.
  • the controller can move the assembly 10 into a desired position relative to the substrate using the handling device.
  • the controller can cause the gas supply member to supply gas into the inner passage 22 and to the substrate before and during operation of the laser source 16.
  • the controller can cause the particle supply member to supply the particles 17.
  • the particles 17 can be accelerated by the gas up to or beyond a critical velocity within the inner passage 22 and directed toward the substrate.
  • the particle supply member supplying the particles 17 can be supplied directly to the divergent sections 23 to flow in the gas supplied by the gas supply member, accelerate within the divergent sections 23, and out of the nozzle assembly via the nozzle exit toward the substrate to coat the substrate.
  • the energy of the laser beam 29 can heat the particles 17 during flight toward the substrate. Because the particles 17 are heated, the particles 17 can plastically deform more readily when the particles 17 impact the substrate. Furthermore, the energy of the laser beam 29 can continue to heat the substrate as the particles 17 are ejected toward the substrate. Thus, the substrate can plastically deform more readily.
  • the handling device can continuously move the assembly 10 to evenly coat the substrate with the particles 17 on predetermined areas. It will be appreciated that the operational mode described above is merely an example and shouldn't be interpreted as limiting.
  • the taught laser coupling methodology provides for the development of a laser beam profile that mimics the internal passage of the nozzle due to progressive internal reflection. Effective energy transfer occurs due to the uniform particle distribution in the divergent section of the nozzle as well as the beam shape modulation, which provides the maximum chance for interaction of the laser beam with the particles. Accordingly, the finished part can be more aesthetically pleasing, can fit better to other parts, and can have better properties due to in-situ annealing. Moreover, the specific claimed combination results in improved performance unattainable by the prior art.
  • a brake rotor 30 is to be coated by a cold spray nozzle assembly 10 described above. It will be appreciated that the coating needs to be applied only to the braking surface 31.
  • the entire braking surface 31 can optionally be coated by moving the cold spray nozzle assembly 10 with the help of a handling device (not shown) such as a robot over the braking surface 31, following a complex and time consuming raster pattern that will ensure a uniform coating thickness, while avoiding coating the unwanted area 38.
  • a combination of rotary motion of the rotor and step wise radial motion of the nozzle assembly may be simpler and less time consuming. It is to be appreciated that for a given coating thickness, the mass of the coating segment 32, 34 and 36 will vary significantly.
  • the effective residence time of the nozzle at a given track will vary considerably as it moves step wise along the radial direction to keep the coating thickness uniform. Further, the desired coating thickness may not be achieved in a single pass as it will likely leave undulations between successive tracks. In cold spray, the underlying undulations/defects continue to grow as the coating builds up. In summary, extensive process optimization will be necessary to achieve a uniform coating on part 30, which yet may not avoid defective coating as well as the need for considenable amount of finish machining. Particularly the growth of defects is problematic while coating such large surfaces.
  • a multi nozzle cold spray apparatus 40 according to the claimed invention is disclosed that can apply a uniform coating of particles 45 across the entire substrate 46 as will be described in greater detail below.
  • the width of particle stream 45 can optionally be identical to the width of the substrate 46, however, that may not be sufficient to ensure a uniform coating.
  • Other important particle stream characteristics are necessary to ensure uniform coating and will be described in greater detail below.
  • the apparatus 40 can be traversed along the length of the substrate 46 to coat the entire surface facing the particle stream 45.
  • the substrate 46 can be traversed while keeping the apparatus 40 stationary to achieve the coating.
  • the exemplary embodiment of the cold spray apparatus 40 according to the claimed invention shown in FIG. 4 includes a nozzle assembly 44 having a substantially straight longitudinal axis X and further comprising of a plurality of internal passages.
  • the number of internal passages can be at least two and optionally can be 3 or 4 or 5 or 6 or many, depending on the width of the required coating as well as the geometric characteristics of the internal passages. Additionally, the geometric characteristics of these internal passages mimic the preferred embodiment 22 ( FIG. 2 ), to a large extent.
  • the apparatus 40 can include a gas supply member 48, operably in communication with a pressure chamber 42, a plurality of particle supply members 43a through 43f, operably in communication with internal passages of the nozzle assembly 44.
  • FIGS. 5B-5E The cross section 57 taken adjacent to the pressure chamber 42 shows five tapered inlets 58a, 58b, 58c, 58d and 58e.
  • cross section 55 includes five passages 56a, 56b, 56c, 56d and 56e, which are substantially smaller than the inlets shown in cross section 57.
  • the cross sectional area of the internal passages (54a, 54b, 54c, 54d and 54e) progressively increase in size toward the exit 49 as shown in cross section 53.
  • there is only one substantially large passage 52 resulting from the merger of the all the passages illustrated above.
  • FIG. 6 is the cross sectional view 60 taken along the symmetric plane of the multi nozzle apparatus 40.
  • the inner passages 64a, 64b, 64c, 64d and 64e extend substantially parallel to the axis X. These passages optionally can be similar (not necessarily same) to each other, however in a preferred embodiment of the claimed invention shown here, they are optionally kept identical. Further details of only one passage 64a are discussed below and it is understood that all other passages (64b, 64c, 64d and 64e) possess similar characteristics.
  • the inner passage 64a includes a nozzle entrance 62a and a nozzle exit 66a at opposite ends thereof. As shown in FIG.
  • the inner passage 64a includes a convergent section 72a adjacent the nozzle entrance 62a and a divergent section 75a adjacent the nozzle exit 66a. More specifically, both the convergent and divergent sections 72a, 75a can be progressively tapered. The convergent section 72a narrows moving away from the entrance 62a, and the divergent section 75a widens moving toward the exit 66a. The convergent section 62a is connected to the divergent section 75a to define a throat 73a ( FIG. 7 ).
  • Each inner passage can receive the accelerating carrier gas from a common pressure chamber 61, or optionally the pressure chamber can be separated.
  • each inner passage includes a plurality of particle supply inlets.
  • the inner passage can include any number of inlets, and the inlets can optionally be disposed in any suitable location.
  • the particle supply inlets 74a, 74b ( FIG. 7 ) each extend transverse to the axis X.
  • the particle supply inlets 74a, 74b can each be disposed at a positive acute angle relative to the axis X and generally toward the exit 66a ( FIG. 6 ).
  • the assembly 40 can include a particle supply source (not shown).
  • the particle supply source can be in (fluid) communication with the inner passages of the nozzle via the particle supply members 43a through 43f.
  • the particle supply member can include one or more tubes that are received in and operably coupled to the inlets.
  • the particles 45 can be supplied from the supply source to flow through the inlets 74a, 74b, through the inner passage 64a, and out of the nozzle exit 66a toward the substrate to coat it with the particles 45.
  • the apparatus assembly 40 includes a laser source 41.
  • the laser source 41 can be of any suitable type, such as a diode laser of a known type.
  • Each inner passage of the nozzle assembly 44 includes a laser beam.
  • the laser source 41 can optionally include a fiber-optic cable 47.
  • fiber 65 brings in one laser beam from a source (not shown), which can optionally split into a plurality of laser beams through a semitransparent mirrors assembly 68a.
  • the semitransparent mirror assembly can be any known type that enable a desired fraction of the laser beam to be transmitted through each mirror and reflecting the remaining fraction in substantially parallel direction of axis X.
  • each reflected fraction of the laser beam is processed through at least one or more (e.g., two shown here) optical element (e.g., lens) assemblies 68b, 68c ( FIG. 6 ).
  • the laser source 41 can be operably coupled to the first branch 69 ( FIG. 6 ) of the pressure tube 42 so as to keep all the laser beams substantially coaxial with the axis X. Further details on the laser beam propagation through the will be provided below.
  • each inner passage of the apparatus assembly 80 can optionally terminate at 85 away from the exit 83.
  • the distance between the throat of the inner passage 81 (divergence section) to the termination point 85 is defined as ML and the between the throat of the inner passage 81 to the exit 83 is defined as DL.
  • the divergence angle of each inner passage will remain constant to maintain a progressive taper of the inner passage in axis X direction, however, the projected exit width 82 of each inner passage will depend on DL.
  • the total maximum opening width 87 of the apparatus assembly 80 will be the sum total of the projected exit width 82 of all channels.
  • a term nozzle overlap is defined as: [(DL-ML)/DL]*100.
  • each internal passage terminates at the exit 83, resulting in a 0% over lap.
  • the wall between each internal passage will have a finite dimension, and therefore, fabricating a nozzle assembly having 0% overlap is practically difficult.
  • the overlap can optionally be between 0.5% and 50%. The influence of the overlap on the particulate characteristics and the resulting coating will be discussed in greater detail below.
  • the particle impact map 90 on a target substrate situated 10 mm away from the nozzle assembly exit 83 ( FIG. 8 ) for different overlap percentages is presented. Further, the corresponding particle velocity magnitude is also superimposed on this map according to a gray scale 97; the lighter shade indicates higher velocity whereas the darker shade indicates lower velocity.
  • -20% overlap which is achieved by simply adjoining a plurality (five here) of nozzles 10, significant gaps 92 in the particle distribution map are observed. These gaps indicate that no coating will be forming on those areas of the target. Further attention is drawn to the zones 91 that have recorded particle impacts indicating a fairly uniform distribution of the particles in those areas.
  • 12/959,523 include a substantially rectangular internal passage geometry along with the side particle injection mode, leads to results that are contrary to conventional wisdom. As will be demonstrated below, an axial injection may not provide such uniform particle velocity as well as uniform distribution across the entire nozzle opening. It will be appreciated that for an overlap of - 20%, the uncoated area 92 is expected to be more than that doesn't have particle impact as the velocities of the adjacent particles (darker shade) are quite low and they are not expected to bond with the target.
  • the significance of the length of the particle impact zone is that, the longer it is, the more target area can be coated in a single traverse of the apparatus 40 ( FIG. 4 ), provided that the impacting particles have the needed critical velocity and uniformity in distribution. Therefore, overlaps beyond a point may not provide any additional benefits, but on the other hand may lead to thicker and narrower coatings that may not be desired. Further insight to optimal overlap percentage can be gained from the particle velocity distribution map shown in FIG. 11 . As will be appreciated, for best coating results, it is desirable that all particles attain a velocity that is higher than the critical velocity of the material being deposited. However, it is practically difficult to get all the particles developing velocities higher than the critical velocity.
  • the preferred overlap can optionally be between 10 and 30%, but, it can be further lower depending upon the material's critical velocity. For example, an overlap of 10 may have enough number of good particles in region 115 for a material whose critical velocity is substantially lower than 112.
  • the laser source 41 provides a laser beam 124a that is transmitted through the entrance 62a ( FIG. 6 ) of the inner passage 64a ( FIG. 6 ) of the nozzle 44 and out of the inner passage 64a via the exit 66a toward the substrate according to an embodiment of the claimed invention.
  • the laser beam 124a is directed substantially parallel to and coaxial to the axis X toward the substrate, although some degree of spread of the beam 124a inward or away from the X axis may optionally be preferred.
  • Laser absorption is a line of sight process. For a central laser beam 124a to pass through the inner passage, the laser beam has to achieve a minimum dimension at or around the throat 63a ( FIG.
  • the inner passage which means it achieves a maximum power density (total power/beam cross sectional areas) near the throat.
  • the particle stream also has to pass through the throat simultaneously with the laser beam.
  • the particles will block a major portion of the laser beam at the throat leading to back reflection, beam distortion, and non-uniform absorption. Back reflection can damage the optics 121a, 122a, 123a.
  • the side injection scheme via 74a and 74b ( FIG.7 ) beyond the throat (i.e. in the divergent section) of the present invention allows the laser beam to interact with the particles beyond its focal point and in the divergent section of the inner passage.
  • any scattered fraction of the laser beam in the divergent section of the inner passage will not travel back to the optics via the throat 63a. Furthermore, due to the progressive divergence of the inner passage beyond the throat as well as the substantially rectangular cross section, forward scattering and multiple internal reflections will be promoted leading to a laser beam profile 125a that mimics the internal passage. The net results are: (a) uniform exposure of the particles to the laser beam leading to uniform absorption, and (b) no back reflection of the laser beam towards the source that can damage the laser optics.
  • a circular beam cross section with Gaussian intensity distribution transforming into a rectangular profile with top hat distribution is caused by this specific combination of particle injection scheme, nozzle shape, as well as laser coupling with the nozzle.
  • the common exit passage 67 ( FIG. 6 ) assumes a substantially rectangular shape as each internal passage. All the modulated laser beam emanating from each inner passage via exit 66a can further scatter and modulate into a single beam 126 mimicking the cross section profile of the common exit passage 67 and thereby causing uniform treatment of the coated material by the residual laser beam emerging out of the nozzle exit 49 ( FIG. 4 ).
  • embodiment 130 of the claimed invention can be utilized to simultaneously coat both braking surfaces of a brake rotor. It includes two multi nozzle cold spray apparatuses 134a and 134b. Apparatus 134b can be kept stationary in place to coat 136 the entire surface 152 simultaneously while rotating the brake rotor with a motor 138. As discussed earlier, the coating mass will vary significantly along the radial direction. Therefore, the injected mass of particles can progressively change from inside channels toward the outmost channels of the apparatus 134b. Further, the beam power passing through each channel can progressively vary to provide equivalent heat energy per unit mass of the coating. This can be achieved by appropriate optical elements used in the laser source 41 ( FIG. 12 ). Accordingly, a uniform coating without raster marks and the related defects can be fabricated rapidly.
  • FIG. 14 presents the simulated particle distribution map as well as the corresponding particles velocity distribution maps when the apparatus 40 was operated in different modes. A 10% over lap was considered in these simulations.
  • Particle distribution map 145 was obtained when the particles and the carrier gas were injected only in one internal passage, which is equivalent to operating one single nozzle 10. It will be appreciated that to run the apparatus in a single channel mode, the carrier gas will continue to flow through the channels that are not in use because the internal passages receive the carrier gas from the common pressure chamber 71. Alternatively, the pressure chamber 71 can be separated to feed each internal passage separately. Referring to FIG.
  • the internal passage 64a can optionally receive carrier gas from pressure tube 151a, which is isolated from the neighboring pressure tube by a wall 152a. It will be appreciated that only a partial view of symmetric half portion 150 of the nozzle assembly 40 is shown in FIG. 15 . Further, the pressure tube 151a is in fluid communication with a gas supply source via control valve 153a. Accordingly, each internal passage (64a, 64b, 64c, 64d and 64e of FIG.6 ) can optionally receive carrier gas from its corresponding pressure tube, which is isolated from its neighboring pressure tube by a wall. Further, each pressure tube is in fluid communication with a gas supply source via its corresponding control valve. Particle distribution map 144 ( FIG.
  • target particle distribution map 160' shows quite non uniform distribution comprising of zones 161 with a lot of particles and zones 162 with a few particles.
  • particle velocity distribution map 162" shows that although some particles achieved significantly higher velocities 164 than the critical velocity 166, but their fraction was low. A large fraction of the particles 163 showed velocities lower than the critical velocity 166.
  • the multi nozzle cold spray apparatus 170 comprises of a common exit 174 that has a parabolic profile 172. If all the internal passages remain same, the overlap will vary along the parabola. To obtain an optimal particulate distribution as well as velocity characteristics, this overlap can be adjusted.
  • the use of such a nozzle to coat a parabolic surface 184 is shown in FIG. 18 . Accordingly, such an apparatus can also be used to build parabolic objects.
  • Another multi nozzle cold spray apparatus 190 is shown in FIG. 19 and it can include a tapered exit 192. Also, this apparatus will have a varying overlap and an optimal overlap needs to be selected to ensure a good deposit.
  • FIG. 19 Another multi nozzle cold spray apparatus 190 is shown in FIG. 19 and it can include a tapered exit 192. Also, this apparatus will have a varying overlap and an optimal overlap needs to be selected to ensure a good deposit.
  • FIG. 19 Another multi nozzle cold spray apparatus 190 is shown in FIG. 19 and it can include a tapered exit
  • the apparatus 200 can be used to build objects having a conical profile 204. Accordingly, many different common exit nozzle profiles can be adopted to achieve different deposition profiles. This also can optionally include supplying a desired amount of particles to each nozzle to achieve differential coating mass on the substrate, which in turn develops a desired geometric profile or conformality.

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  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Metallurgy (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Health & Medical Sciences (AREA)
  • Optics & Photonics (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Health & Medical Sciences (AREA)
  • Nozzles (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Spray Control Apparatus (AREA)
EP17862179.3A 2016-10-17 2017-10-16 Cold spray apparatus with large area conformal deposition ability Active EP3526369B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US15/295,050 US10119195B2 (en) 2009-12-04 2016-10-17 Multichannel cold spray apparatus
PCT/US2017/056766 WO2018075395A1 (en) 2016-10-17 2017-10-16 Cold spray apparatus with large area conformal deposition ability

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EP3526369A1 EP3526369A1 (en) 2019-08-21
EP3526369A4 EP3526369A4 (en) 2020-04-29
EP3526369B1 true EP3526369B1 (en) 2024-09-18

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KR (1) KR102361006B1 (ja)
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CA (1) CA3040863A1 (ja)
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US9335296B2 (en) 2012-10-10 2016-05-10 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
KR102523509B1 (ko) 2019-09-19 2023-04-18 웨스팅하우스 일렉트릭 컴퍼니 엘엘씨 콜드 스프레이 침착물의 현장 접착 테스트를 수행하기 위한 장치 및 사용 방법
CN113414042B (zh) * 2021-04-02 2024-08-09 国网宁夏电力有限公司检修公司 一种用于隔离开关电触头的修复装置

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KR102361006B1 (ko) 2022-02-09
JP7194439B2 (ja) 2022-12-22
WO2018075395A1 (en) 2018-04-26
CA3040863A1 (en) 2018-04-26
EP3526369A4 (en) 2020-04-29
JP2019537663A (ja) 2019-12-26
KR20190057398A (ko) 2019-05-28
EP3526369A1 (en) 2019-08-21
AU2017345219A1 (en) 2019-05-02
MX2019004515A (es) 2019-09-26
CN110073033B (zh) 2022-02-01

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