Cold-Sprayed Barrier Layer for Thermal Softening Prevention
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Summary
Problems
Additive friction stir deposition of high-strength non-heat treatable alloys like Scalmalloy onto Al—Zn alloy plates results in thermal softening, which is difficult to mitigate without incurring significant costs or introducing thermal distortion/stress issues.
Innovation solutions
A method involving a cold-sprayed Al—Mg—(Sc, Zr) based alloy as a barrier layer between the heat treatable aluminium alloy substrate and the additive friction stir deposition layer, which acts as a thermal barrier to prevent thermal softening during the deposition process.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If additive friction stir deposition is performed directly on the heat treatable aluminium alloy substrate, then the deposition process can proceed, but thermal softening of the substrate occurs
Why choose this principle:
A cold-sprayed barrier layer comprising an non-heat treatable aluminium alloy is introduced between the heat treatable aluminium alloy substrate and the additive friction stir deposition process. This intermediary layer acts as a thermal barrier that prevents direct thermal contact, thereby protecting the substrate from thermal softening while allowing the deposition process to proceed at high rates
Principle concept:
If pre-chilling the substrate is used to mitigate thermal softening, then thermal degradation is reduced, but massive expense and thermal distortion/stress issues are introduced
Why choose this principle:
Instead of using a complex pre-chilling system, a simple cold-sprayed barrier layer is applied to the substrate surface. This layer provides thermal protection without requiring external chilling equipment, avoiding the associated complexity, expense, and thermal distortion issues
Application Domain
Data Source
AI summary:
A method involving a cold-sprayed Al—Mg—(Sc, Zr) based alloy as a barrier layer between the heat treatable aluminium alloy substrate and the additive friction stir deposition layer, which acts as a thermal barrier to prevent thermal softening during the deposition process.
Abstract
A method of manufacturing an article is described. At S 102 , the method comprises obtaining a first layer having a first face and a reverse second face, wherein the first layer comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy. At S 104 , the method comprises providing a second layer on the first face of the first layer by cold spraying particles comprising a second metal thereupon, wherein the second metal is a second aluminium alloy. At S 106 , the method comprises depositing a third layer on the second layer by additive friction stir deposition using a third metal, wherein the third metal is a third aluminium alloy.