EP4735183A2 - Nozzle design for high-velocity deposition of particles - Google Patents

Abstract

In accordance with embodiments of the present disclosure, a nozzle may include a housing, a bore centrally disposed through the housing, the bore comprising an inlet and a main outlet; and one or more pressure relief outlets formed in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing.

Description

NOZZLE DESIGN FOR HIGH-VELOCITY DEPOSITION OF PARTICLES

RELATED APPLICATION

The present disclosure claims priority to United States Provisional Application Serial No. 63/510397 filed June 27, 2023, which is incorporated by reference herein in its entirety.

FIELD OF DISCLOSURE

The present disclosure relates in general to methods and systems for the high- velocity deposition of particles, including micro-scale and nano-scale particles of metal, ceramic, or other material, using a nozzle.

BACKGROUND

Cold spray and micro-cold spray are techniques that may be used to produce thick (e.g., 1-100 pm), nearly full density metal and ceramic films using a feedstock of dry particles, typically 200 nm to 5 pm in diameter in micro-cold spray and typically 1 pm to 75 pm in diameter for cold spray, using known approaches. Micro-cold spray techniques may also be referred to as aerosol deposition, low pressure cold spray, vacuum cold spray, or vacuum kinetic spraying. In micro-cold spray, particles may be aerosolized in a low pressure carrier gas and then accelerated through a nozzle into a vacuum chamber. In cold spray, particles may be aerosolized in a high pressure carrier gas and then accelerated through a nozzle into an ambient pressure chamber. For both micro-cold spray and cold spray, the particles may impact onto a substrate at a high enough velocity where particles may deform and adhere to the substrate.

Using existing techniques, deposition efficiencies for particles may often be less than 10%, due to a variety of causes such as material loss due to fracture of the particles, deflection of smaller particles due to the presence of a bow shock in the supersonic gas, and erosion due to high kinetic energy impacts of larger particles. As is known in the field of aerodynamics, a bow shock, also called a detached shock or bowed normal shock, is a curved propagating disturbance wave characterized by an abrupt, nearly discontinuous, change in pressure, temperature, and density. A bow shock may occur when a supersonic flow encounters a body, around which the necessary deviation angle of the flow is higher than the maximum achievable deviation angle for an attached oblique shock. Then, the oblique shock transforms into a curved detached shock wave. As bow shocks occur for high flow deflection angles, they are often seen forming around blunt bodies, because of the high deflection angle that the body imposes to the flow around it.

Supersonic spray nozzles result in a bow shock that the particles travel through before impacting the substrate being coated. A stagnation region may form downstream of the bow shock where the gas is stagnant or nearly stagnant and compressed to a high density, which slows or deflects particles that are small or have a low material density (typical of ceramics). Consequently, smaller particles may not deposit at the high velocities required to produce high quality, dense films.

Numerical studies of particle velocity have indicated the slowing of small particles is strongly dependent on both the density and thickness of the stagnant gas region upstream of the substrate surface (i.e., the stagnation region). The density within the stagnation region has also been shown to be linearly dependent on the nozzle inlet pressure. Experimentally, a reduction in pressure downstream of the shock wave results in increased film thickness, indicating that, by minimizing the effects of the stagnation region, film deposition rate and efficiency can be improved. For small particles to maintain sufficient impact velocity while passing through the stagnation region, the pressure within the stagnation region must be low enough that minimal particle deceleration occurs while, al the same time, a high gas velocity is maintained to sufficiently accelerate particles through the nozzle.

Accordingly, systems and methods that enable minimizing pressure downstream of the bow shock and in the stagnation region may be desired.

SUMMARY

In accordance with the teachings of the present disclosure, the disadvantages and problems associated with existing approaches for depositing particles using cold spray and micro-cold spray techniques may be reduced or eliminated.

In accordance with embodiments of the present disclosure, a nozzle may include a housing, a bore centrally disposed through the housing, the bore comprising an inlet and an outlet, and one or more pressure relief outlets formed in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing.

In accordance with these and other embodiments of the present disclosure, a method for forming a nozzle may comprise centrally disposing a bore through a housing, the bore comprising an inlet and a main outlet and forming one or more pressure relief outlets in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing.

In accordance with these and other embodiments of the present disclosure, a method may include fluidically coupling an inlet of a nozzle to a source of pressurized aerosol, wherein the nozzle has a housing, a bore centrally disposed through the housing, the bore comprising an inlet and an outlet, and one or more pressure relief outlets formed in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing. The method may also include positioning the main outlet proximate to a substrate such that particles of the pressurized aerosol accelerated through the bore are deposited on the substrate.

In accordance with these and other embodiments of the present disclosure, a system for high-velocity deposition of particles onto a substrate, may include a source of pressurized aerosol and a nozzle having an inlet coupled to the source of pressurized aerosol, the nozzle having a housing, a bore centrally disposed through the housing, the bore comprising an inlet and an outlet, and one or more pressure relief outlets formed in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing.

Technical advantages of the present disclosure may be readily apparent to one having ordinary skill in the art from the figures, description and claims included herein. The objects and advantages of the embodiments will be realized and achieved at least by the elements, features, and combinations particularly pointed out in the claims. It is to be understood that both the foregoing general description and the following detailed description are examples and explanatory and are not restrictive of the claims set forth in this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:

FIGURE 1 illustrates a block diagram of a system for high-velocity deposition of particles using micro-cold spray, in accordance with embodiments of the present disclosure;

FIGURE 2A illustrates a side elevation view of an example nozzle for use in high-velocity deposition of particles, in accordance with embodiments of the present disclosure;

FIGURES 2B and 2C illustrate isometric perspective views of a side elevation view of the example nozzle shown in FIGURE 2A, in accordance with embodiments of the present disclosure;

FIGURE 3 illustrates an axial cross-sectional view of the nozzle depicted in FIGURE 2A, in accordance with embodiments of the present disclosure;

FIGURE 4A illustrates an isometric perspective view of a lateral cross-section of the example nozzle shown in FIGURE 2A, in accordance with embodiments of the present disclosure;

FIGURE 4B illustrates an end elevation view of a lateral cross-section of the example nozzle shown in FIGURE 2A, in accordance with embodiments of the present disclosure;

FIGURE 5 illustrates an axial cross-sectional view of the nozzle depicted in FIGURE 2A annotated with selected physical parameters of the nozzle, in accordance with embodiments of the present disclosure;

FIGURE 6 illustrates an isometric perspective view of another example nozzle for use in high-velocity deposition of particles, in accordance with embodiments of the present disclosure; and

FIGURE 7 illustrates an axial cross-sectional view of the nozzle depicted in FIGURE 6, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

The description below sets forth example embodiments according to this disclosure. Further example embodiments and implementations will be apparent to those having ordinary skill in the art. Further, those having ordinary skill in the art will recognize that various equivalent techniques may be applied in lieu of, or in conjunction with, the embodiment discussed below, and all such equivalents should be deemed as being encompassed by the present disclosure.

FIGURE 1 illustrates a block diagram of a system 100 for high-velocity deposition of particles using micro-cold spray, in accordance with embodiments of the present disclosure. As shown in FIGURE 1, system 100 may include a carrier gas supply 102, a particle supply 104, a feed controller 106, a deagglomerator 108, a vacuum chamber 1 10, a nozzle 1 12 within vacuum chamber 1 10, a vacuum pump 1 14 fluidically coupled to vacuum chamber 110, and a stage 116 within vacuum chamber 110 for positioning a substrate 118 relative to nozzle 112 within vacuum chamber 110.

A similar system may be used for cold spray deposition of particles. For example, for cold spray deposition, the upstream pressure may be elevated to tens or hundreds of atmospheres and the pressure downstream of the nozzle may be at atmospheric pressure, and a thus vacuum chamber (e.g., vacuum chamber 110) may not be present.

Carrier gas supply 102 may include any suitable container or housing for a carrier gas (e.g., air, helium, argon, or nitrogen), and may comprise pressurized storage for such carrier gas. In some embodiments, the pressure of the gas may be near atmospheric pressure. In other embodiments, the pressure may be elevated to as high as several hundred atmospheres.

Feed controller 106 may be fluidically coupled to carrier gas supply 102 and may comprise any suitable system, device, or apparatus for controlling a rate of particles from particle supply 104. For example, in some embodiments, feed controller 106 may comprise a screw feeder.

Particle supply 104 may include any suitable container or housing for solid particles (e.g., metal, metallic alloy, semi-conductor, polymer, ceramic, composites of any combination of the foregoing, etc.). In some embodiments, such particles may be in the form of a fine powder (e.g., a power of particles 10 nm to 5 pm in diameter for micro-cold spray applications or 100 nm to 75 pm in diameter for cold spray applications).

Accordingly, feed controller 106 may output an aerosol of solid particles to deagglomerator 108. Deagglomerator 108 may comprise any suitable system, device, or apparatus configured to deagglomerate solid particles from each other in the aerosol. Deagglomeration of particles may be useful in micro-cold spray applications so that individual particles impact substrate 118 rather than agglomerates. Because agglomerates may absorb significant impact energy through fracture and particle rearrangement, this absorbed energy may not then be available to deform and stick the particles to substrate 118. Thus, deagglomerator 108 may enhance the uniformity of the sprayed aerosol density because there is a range of residence times before the powder is fed into nozzle 112. In some embodiments, deagglomerator 108 may be implemented with a motor configured to cause rotation of discs at a high angular velocity, such that as the aerosol of solid particles passes through deagglomerator 108, such spinning discs shear apart agglomerates of particles. In some embodiments, a deagglomerator may not be necessary and thus may be omitted, depending on the characteristics of the powder being deposited.

Due to pressure differentials between carrier gas supply 102 and vacuum chamber 110, the aerosolized particles may be accelerated through nozzle 112, and onto substrate 118, in order to deposit a film of the particles onto substrate 118. Example embodiments of nozzle 112 are described in greater detail below with reference to FIGURES 2 through 7.

Vacuum chamber 110 may comprise any sealed container or housing from which air and other gases may be removed (e.g., via vacuum pump 114) to create a low-pressure environment within such container. Vacuum pump 114 may include any system, device, or apparatus configured to remove gas molecules from the sealed volume of vacuum chamber 1 10 to create a vacuum within vacuum chamber 1 10.

Stage 116 may comprise any suitable system, device, or apparatus configured to cany or otherwise hold and position substrate 118. In some embodiments, stage 116 may comprise or may be coupled to a motor or other device configured to vertically or horizontally translate stage 116 relative to nozzle 112, in order to enable a stream of aerosolized particles sprayed from nozzle 112 to impinge upon desired locations upon the surface of substrate 118. In cold spray deposition, substrate 118 may be fixed and nozzle 112 may be placed on a movable stage or robotic arm.

Substrate 118 may comprise any suitable substrate of material upon which particles within the aerosolized particles sprayed from nozzle 1 12 may be deposited using cold spray or micro-cold spray techniques. For example, substrate 118 may include any solid material (e.g., metal, metallic alloy, semi-conductor, polymer, ceramic, a composite of any combination of foregoing, etc.).

FIGURE 2 A illustrates a side elevation view of an example nozzle 112A for use in high-velocity deposition of particles, in accordance with embodiments of the present disclosure. FIGURES 2B and 2C illustrate isometric perspective views of nozzle 112A, in accordance with embodiments of the present disclosure. FIGURE 3 illustrates an axial cross-sectional view of nozzle 112A, in accordance with embodiments of the present disclosure. FIGURE 4A illustrates an isometric perspective view of a lateral cross-section of nozzle 112A, in accordance with embodiments of the present disclosure. FIGURE 4B illustrates an end elevation view of a lateral cross-section of nozzle 112A, in accordance with embodiments of the present disclosure. Nozzle 112A shown in FIGURES 2A-4B may be used to implement nozzle 112 depicted in FIGURE 1.

As shown in FIGURES 2A-4B, nozzle 112A may comprise a housing 202 with a bore 204 centrally formed through housing 202 from one end of housing 202 to an opposite end of housing 202. As also depicted in FIGURE 3, bore 204 may include a converging portion 206 extending from an inlet 210 of bore 204 and decreasing in a cross-sectional area from inlet 210. Further, bore 204 may include a diverging portion 208 fluidically coupled to converging portion 206 at a throat 212 of bore 204 at which a cross-sectional area of bore 204 is at its minimum, and wherein diverging portion 208 extends from throat 212 to a main outlet 214 of bore 204 and increases in a cross- sectional area from throat 212 to main outlet 214. Further, nozzle 112A may include one or more pressure relief outlets 216 formed in housing 202, each of one or more pressure relief outlets 216 extending from diverging portion 208 of bore 204 and through a wall 218 of housing 202.

In operation, inlet 210 may be fluidically coupled to a source (e.g., carrier gas supply 102, particle supply 104, feed controller 106, deagglomerator 108) of a pressurized aerosol of solid particles (metal, metallic alloy, ceramic, etc.) and main outlet 214 may be positioned proximate to substrate 118 within vacuum chamber 110, with a gas pressure at main outlet 214 significantly smaller than that at inlet 210. As a result of the pressure differential, particles of the pressurized aerosol may be accelerated from the source, through bore 204 from inlet 210 to main outlet 214, and onto the substrate proximate to main outlet 214, in order to deposit a film of the particles onto the substrate.

Pressure relief outlets 216 may reduce pressure downstream of main outlet 214 (e.g., in the stagnation region near the substrate) as compared to converging-diverging nozzles without any such pressure relief outlets. Such reduced pressure may allow small particles to maintain high velocities once they exit through main outlet 214 of nozzle 112A and pass through the bow shock, thus leading to more efficient deposition of particles on substrate 118.

Sizes (e.g., lengths, cross-sectional areas) of converging portion 206, diverging portion 208, and the one or more pressure relief outlets 216 may be of any suitable size, and may be selected based on factors including, but not limited to, the material being deposited, the substrate for deposition, sizes of particles of the material, the composition and pressure of the carrier gas used, and/or any other suitable factors. Similarly, geometries (e.g., angle of convergence, angle of divergence, angles of pressure relief outlets 216 relative to diverging portion 208), may be selected based on factors including, but not limited to, the material being deposited, the substrate for deposition, sizes of particles of the material, the composition and pressure of the earner gas used, and/or any other suitable factors.

In some embodiments, an angle between an axis of pressure relief outlets 216 (e.g., such axis defined as a line defined by a center of an inlet for a pressure relief outlet 216 to a center of an outlet for the pressure relief outlet 216) and an axis of bore 204 (e.g., such axis defined as a line defined by a center of main outlet 214 and a center of an inlet) may be less than 135°, wherein such angle includes the center of an outlet for the pressure relief outlet 216 and the center of main outlet 214.

As an example, as seen in FIGURE 4B, in embodiments with three pressure relief outlets 216 arranged axially around nozzle 112A at the same distance from inlet 210, each pressure relief outlet 216 may have an axial angle of 0B with wall 218 between each adjacent pressure relief outlet having an axial angle of 0A. Example values for such axial angles may be 0A = 15° and 0b = 105°, but such axial angles may be selected based on factors including, but not limited to, the material being deposited, the substrate for deposition, sizes of particles of the material, the composition and pressure of the carrier gas used, and/or any other suitable factors.

As a further example, FIGURE 5 illustrates an axial cross-sectional view of nozzle 112A annotated with selected physical parameters of nozzle 112A, in accordance with embodiments of the present disclosure. The selected physical parameters depicted in FIGURE 5 include a diverging angle 0i of diverging portion 208 upstream of pressure relief outlet 216, a diverging angle 02 of diverging portion 208 downstream of pressure relief outlet 216, channel angle ©channel of pressure relief outlet 216 with respect to the axis of bore 204, a relative placement L2/L1 of pressure relief outlet 216 along the axis of bore 204, the inset ch/di of pressure relief outlet 216 into the aerosol stream, and the width dchannei of pressure relief outlet 216. Such parameters may also be selected based on factors including, but not limited to, the material being deposited, the substrate for deposition, sizes of particles of the material, the composition and pressure of the carrier gas used, and/or any other suitable factors. For a powder with 80 nm particles with a carrier gas of nitrogen with an inlet pressure of 40-44 kPa and a powder of 40 nm particles with a carrier gas of helium with an inlet pressure of 13-20 Pa on a polished single-crystal silicon wafer substrate, and with a nozzle 112 A with throat 212 having a length of 1 mm and diameter of 1 mm and having a channel length 100 mm from throat 212 to main outlet 214, example parameter values may be: diverging angle 9i: l°-2° diverging angle O2: 2° channel angle Ochannei: 10° relative placement L2/L1: < 0.65 inset dz/di: 0.75 width dchannei: 5 mm

However, such parameters may be different based on factors including, but not limited to, the material being deposited, the substrate for deposition, sizes of particles of the material, the composition and pressure of the carrier gas used, and/or any other suitable factors.

Nozzle 112A as described herein may be constructed from any suitable material (e.g., polymer, metal, ceramic, or a composite of one of more of such materials) and in any suitable manner, including without limitation the use of additive manufacturing (i.e., three-dimensional printing), or conventional techniques such as casting and/or machining. In some embodiments, nozzle 112A may be constructed using additive manufacturing or conventional techniques, and pressure relief outlets 216 through the sides of housing 202 may be created with a tool (e.g., a drill, blade, mill, and/or broach). In some embodiments, nozzle 112A may be formed from a plurality of components mechanically joined together.

Although nozzle 112A as shown and described above is depicted as having three pressure relief outlets 216 through the sides of housing 202 all at the same approximate lateral distance from throat 212, it is understood that in some embodiments, nozzle 112A may have fewer (e.g., 1 or 2) or more (e.g., 4 or more) pressure relief outlets 216 through the sides of housing 202 all at the same approximate lateral distance from throat 212.

Furthermore, nozzle 1 12 is not limited to only having pressure relief outlets at a particular lateral distance from throat 212. For example, in some embodiments pressure relief outlets 216 may be located at different distances from throat 212.

FIGURE 6 illustrates an isometric perspective view of an example nozzle 112B for use in high-velocity deposition of particles, in accordance with embodiments of the present disclosure. FIGURE 7 illustrates an axial cross-sectional view of nozzle 1 12B, in accordance with embodiments of the present disclosure. Nozzle 112B shown in FIGURES 6 and 7 may be used to implement nozzle 112 depicted in FIGURE 1.

Nozzle 112B may be similar in many respects to nozzle 112 A. Accordingly, only particular differences between nozzle 112A and nozzle 1 12B may be described below.

One particular difference between nozzle 112A and nozzle 112B is that nozzle 112B may include pressure relief outlets 216 located at different distances from throat 212. Although FIGURES 6 and 7 depict nozzle 112B having pressure relief outlets 216 located at three different distances from throat 212, it is understood that nozzle 112B may have pressure relief outlets 216 located at fewer than three distances (e.g., two different distances) or more than three distances (e.g., four or more different distances) from throat 212.

Nozzles 112A and 112B as described herein may be constructed from any suitable material (e.g., polymer, metal, ceramic, or a composite of one of more of such materials) and in any suitable manner, including without limitation the use of additive manufacturing (i.e., three-dimensional printing), casting, and/or machining. In some embodiments, nozzles 112A and 112B may be constructed using conventional techniques, with a tool (e.g., a drill, blade, mill, and/or broach) used to create pressure relief outlets 216 through the sides of housing 202.

Advantageously, the nozzle disclosed herein may enable deposition of particles smaller than known approaches. For example, the nozzle disclosed herein may enable deposition of particles as small as approximately 10 nm for micro-cold spray and as small as approximately 100 nm for cold spray.

As used herein, when two or more elements are referred to as “coupled” to one another, such term indicates that such two or more elements are in mechanical communication, whether connected indirectly or directly, with or without intervening elements.

This disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the example embodiments herein that a person having ordinary skill in the art would comprehend. Similarly, where appropriate, the appended claims encompass all changes, substitutions, variations, alterations, and modifications to the example embodiments herein that a person having ordinary skill in the art would comprehend. Moreover, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, or component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative. Accordingly, modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. For example, the components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components and the methods described may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order. As used in this document, “each” refers to each member of a set or each member of a subset of a set.

Although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described above.

Unless otherwise specifically noted, articles depicted in the drawings are not necessarily drawn to scale.

All examples and conditional language recited herein are intended for pedagogical objects to aid the reader in understanding the disclosure and the concepts contributed by the inventor to furthering the art, and are construed as being without limitation to such specifically recited examples and conditions. Although embodiments of the present disclosure have been described in detail, it should be understood that various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the disclosure.

Although specific advantages have been enumerated above, various embodiments may include some, none, or all of the enumerated advantages. Additionally, other technical advantages may become readily apparent to one of ordinary skill in the art after review of the foregoing figures and description.

To aid the Patent Office and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim elements to invoke 35 U.S.C. § 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.

Claims

WHAT IS CLAIMED IS:

1. A nozzle comprising: a housing; a bore centrally disposed through the housing, the bore comprising an inlet and a main outlet; and one or more pressure relief outlets formed in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing.

2. The nozzle of Claim 1 , wherein an angle between the bore and at least one of the one or more pressure relief outlets is less than 135°, wherein the angle is defined by a first axis defined as a line including a center of an inlet for the one pressure relief outlet and a center of an outlet for the one pressure relief outlet and a second axis defined as a line including a center of the main outlet and a center of the inlet, and wherein such angle includes the center of the outlet for the one pressure relief outlet and the center of the main outlet.

3. The nozzle of Claim 1, wherein the housing comprises a polymer material.

4. The nozzle of Claim 1 , wherein the housing comprises metal.

5. The nozzle of Claim 1, wherein the housing comprises ceramic.

6. The nozzle of Claim 1, wherein the one or more pressure relief outlets are formed in the housing at the same lateral distance from the main outlet.

7. The nozzle of Claim 1 , wherein at least two of the one or more pressure relief outlets are formed in the housing at different lateral distances from the main outlet.

8. The nozzle of Claim 1, wherein the bore comprises: a converging portion extending from the inlet of the bore and decreasing in a cross-sectional area from the inlet; and a diverging portion, the diverging portion fhiidically coupled to the converging portion at a throat of the bore at which a cross-sectional area of the bore is at its minimum, and the diverging portion extending from the throat to the main outlet of the bore and increasing in a cross-sectional area from the throat to the main outlet.

9. The nozzle of Claim 8, wherein each of the one or more pressure relief outlets extend from the diverging portion of the bore and through a wall of the housing.

10. A method for forming a nozzle comprising: centrally disposing a bore through a housing, the bore comprising an inlet and a main outlet; and forming one or more pressure relief outlets in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing.

11. The method of Claim 10, further comprising forming the nozzle such that an angle between the bore and at least one of the one or more pressure relief outlets is less than 135°, wherein the angle is defined by a first axis defined as a line including a center of an inlet for the one pressure relief outlet and a center of an outlet for the one pressure relief outlet and a second axis defined as a line including a center of the main outlet and a center of the inlet, and wherein such angle includes the center of the outlet for the one pressure relief outlet and the center of the main outlet.

12. The method of Claim 10, comprising forming the nozzle using one or more of casting, machining, and additive manufacturing.

13. The method of Claim 10, further comprising forming the one or more pressure relief outlets by creating one or more openings in the housing.

14. The method of Claim 13, further comprising creating one or more openings in the housing by drilling the one or more openings through the housing.

15. The method of Claim 13, further comprising creating one or more openings in the housing by cutting the one or more openings through the housing using a blade.

16. The method of Claim 10, comprising forming the nozzle with a polymer material.

17. The method of Claim 10, comprising forming the nozzle with a metal material.

18. The method of Claim 10, comprising forming the nozzle with a ceramic material.

19. The method of Claim 10, comprising forming the one or more pressure relief outlets in the housing at the same lateral distance from the main outlet.

20. The method of Claim 10, comprising forming at least two of the one or more pressure relief outlets in the housing at different lateral distances from the main outlet.

21. The method of Claim 10, forming the bore comprises: forming a converging portion extending from the inlet of the bore and decreasing in a cross-sectional area from the inlet; and forming a diverging portion, the diverging portion fluidically coupled to the converging portion at a throat of the bore at which a cross-sectional area of the bore is at its minimum, and the diverging portion extending from the throat to the main outlet of the bore and increasing in a cross-sectional area from the throat to the main outlet.

22. The method of Claim 21, further comprising forming each of the one or more pressure relief outlets such that each of the one or more pressure relief outlets extend from the diverging portion of the bore and through a wall of the housing.

23. A method comprising: fluidically coupling an inlet of a nozzle to a source of pressurized aerosol, the nozzle having: a housing; a bore centrally disposed through the housing, the bore comprising an inlet and a main outlet; and one or more pressure relief outlets formed in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing; and; positioning the main outlet proximate to a substrate such that particles of the pressurized aerosol accelerated through the bore are deposited on the substrate.

24. The method of Claim 23, wherein an angle between the bore and at least one of the one or more pressure relief outlets is less than 135°, wherein the angle is defined by a first axis defined as a line including a center of an inlet for the one pressure relief outlet and a center of an outlet for the one pressure relief outlet and a second axis defined as a line including a center of the main outlet and a center of the inlet, and wherein such angle includes the center of the outlet for the one pressure relief outlet and the center of the main outlet.

25. The method of Claim 23, wherein the housing is made from nylon.

26. The method of Claim 23, wherein the particles comprise a ceramic.

27. The method of Claim 23, wherein the particles comprise a metal.

28. The method of Claim 23, wherein the particles comprise a metallic alloy.

29. The method of Claim 23, wherein the one or more pressure relief outlets are formed in the housing at the same lateral distance from the main outlet.

30. The method of Claim 23, wherein at least two of the one or more pressure relief outlets are formed in the housing at different lateral distances from the main outlet.

31. The method of Claim 23, wherein the bore comprises: a converging portion extending from the inlet of the bore and decreasing in a cross-sectional area from the inlet; and a diverging portion, the diverging portion fluidically coupled to the converging portion at a throat of the bore at which a cross-sectional area of the bore is at its minimum, and the diverging portion extending from the throat to the main outlet of the bore and increasing in a cross-sectional area from the throat to the main outlet.

32. The method of Claim 31, wherein each of the one or more pressure relief outlets extend from the diverging portion of the bore and through a wall of the housing.

33. A system for high-velocity deposition of particles onto a substrate, comprising: a source of pressurized aerosol; and a nozzle having an inlet coupled to the source of pressurized aerosol, the nozzle having: a housing; a bore centrally disposed through the housing, the bore comprising an inlet and an outlet; and one or more pressure relief outlets formed in the housing, each of the one or more pressure relief outlets extending from the bore and through a wall of the housing.