Cold spray system and method for coating cast materials

Abstract

A method for processing a metal substrate may include receiving a metal substrate and additively depositing metal particles by cold spraying the metal particles onto the metal substrate to produce a cold spray coating adhered to the metal substrate. The method may optionally include rolling the metal substrate after depositing the metal particles to form the cold spray coating or before depositing the metal particles to form the cold spray coating. The method may optionally include heating the metal substrate prior to cold spraying. The metal processing system may include a cold spray system for additively depositing metal particles onto the metal substrate and at least one piece of equipment for further processing the metal substrate.

Description

[Technical field]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 267,128, filed January 25, 2022, and entitled COLD SPRAY SYSTEMS AND METHODS FOR COATING CAST MATERIALS, the contents of which are incorporated by reference in their entirety herein.

[0002] This application relates generally to metallurgy, and more specifically to a system and method for applying a coating onto a cast material. [Background technology]

[0003] Continuous casting of metals such as aluminum or aluminum alloys often results in cast products having surface defects that are difficult to remove or mask by conventional techniques, and the presence of such surface defects limits the potential uses of such products. Furthermore, removing such surface defects by facing or surface removal results in lost process time and cost. Thus, there is a lack of technology to produce continuously cast materials with improved surfaces. Summary of the Invention

[0004] The embodiments covered by this patent are defined by the claims below, and not by this Summary. This Summary is a high level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. This subject matter should be understood by reference to the entire specification of this patent, any or all drawings, and appropriate portions of the claims.

[0005] According to certain embodiments, a method of processing a metal substrate includes additively depositing metal particles by cold spraying the metal particles onto the metal substrate to produce a cold spray coating adhered to the metal substrate, and the method includes rolling the metal substrate with the cold spray coating using a rolling mill.

[0006] According to various embodiments, a method of processing a metal substrate includes rolling the metal substrate with a rolling mill and additively depositing metal particles by cold spraying the metal particles onto the rolled metal substrate to produce a cold spray coating adhered to the rolled metal substrate.

[0007] According to some embodiments, a method of processing a heated metal substrate includes receiving a heated metal substrate in a cold spray system and additively depositing metal particles by cold spraying the metal particles onto the metal substrate to produce a cold spray coating adhered to the metal substrate.

[0008] According to various embodiments, a metal processing system includes a cold spray system for additively depositing metal particles by cold spraying the metal particles onto a metal substrate to produce a cold spray coating adherent to the metal substrate. The metal processing system may include a rolling mill upstream or downstream from the cold spray system.

[0009] According to certain embodiments, a metal processing system includes a heater for heating a metal substrate, and a cold spray system downstream from the heater for additively depositing metal particles by cold spraying the metal particles onto the heated metal substrate to produce a cold spray coating adhered to the metal substrate.

[0010] The various embodiments described herein may include additional systems, methods, features, and advantages that may not necessarily be expressly disclosed herein, but will be apparent to one of ordinary skill in the art upon review of the following detailed description and the accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within this disclosure and protected by the accompanying claims.

[0011] This specification refers to the accompanying drawings in which: The use of like reference numbers in different drawings is intended to indicate the same or similar elements. [Brief description of the drawings]

[0012] [Figure 1] 1 illustrates a metal processing system including a cold spray system, according to an embodiment. [Diagram 2] 1 shows a portion of a metal substrate taken from Box 2 of FIG. 1 being processed by the metal processing system of FIG. [Diagram 3] 2 illustrates a process for cold spraying a metal substrate using the metal processing system of FIG. 1, according to an embodiment. [Figure 4] 2 illustrates another process for cold spraying a metal substrate using the metal processing system of FIG. 1, according to an embodiment. [Diagram 5] 1 illustrates a method of processing a metal substrate, according to an embodiment. [Figure 6] 1 illustrates another method of processing a metal substrate, according to an embodiment. [Figure 7] 1 is an image of a metal substrate with a cold spray coating, according to an embodiment. [Figure 8] 8 is an image of a metal substrate with the cold spray coating of FIG. 7 after rolling, according to an embodiment. [Figure 9] 1 is an image of a metal substrate with a cold spray coating, according to an embodiment. [Figure 10] 1 is an image of a metal substrate with a cold spray coating, according to an embodiment. [Figure 11]1 is an image of a metal substrate with a cold spray coating, according to an embodiment. [Figure 12] 1 is an image of a metal substrate with a cold spray coating, according to an embodiment. [Figure 13] 12 is another image of the metal substrate of FIG. 11 after rolling, according to an embodiment. [Figure 14] 1 is a chart showing the surface roughness of a metal substrate with a cold spray coating after rolling, according to an embodiment. [Figure 15] 1 is a chart showing bend angle of a metal substrate with a cold spray coating after rolling, according to an embodiment. [Figure 16] 1 is an image of intergranular corrosion of a metal substrate without a cold spray coating after 24 hours and after rolling. [Figure 17] 1 is an image of intergranular corrosion after 24 hours of rolling a metal substrate with a cold spray coating, according to an embodiment. [Figure 18] 17 is an image of intergranular corrosion of the metal substrate of FIG. 16 48 hours after rolling. [Figure 19] 18 is an image of intergranular corrosion of the metal substrate of FIG. 17 after 48 hours of exposure. [Figure 20] 4A-C are images of metal substrates with cold spray coatings according to embodiments. [Figure 21] 1 illustrates a metal substrate with a cold spray coating according to an embodiment compared to a metal substrate without the cold spray coating. [Figure 22] 1 illustrates a metal substrate with a cold spray coating according to an embodiment compared to a metal substrate without the cold spray coating. [Diagram 23] AB show the corrosion of a metal substrate with a cold spray coating according to an embodiment compared to the corrosion of a metal substrate without the cold spray coating. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Described herein are cold spray systems and methods for forming cold spray coatings on metal substrates, as well as metal products with cold spray coatings. The systems and methods described herein can be used with any metal, but they may be particularly useful for aluminum or aluminum alloys. Advantageously, the cold spray coating may be deposited on the metal substrate during metal processing, such as after continuous casting, after direct chill casting, before rolling, after rolling, etc. In some aspects, the cold spray coating applied on the heated surface may create an interface by mechanical and / or chemical bonding to provide continuous protection to the metal product during use, which may be similar to a product formed using "fusion casting", which may also be referred to under the trade name FUSION™ (Novelis, Inc., Atlanta, US), and is described, for example, in U.S. Pat. No. 7,472,740, the contents of which are incorporated herein by reference. In various embodiments, the cold spray coating may mask exudates and / or other defects on the surface of the metal substrate without reducing mechanical properties, thereby allowing the metal substrate to be used in consumer products, exterior products, and / or other high quality products (referred to herein as "Class A" products). In some embodiments, the cold spray coating may improve the properties of the metal substrate, including but not limited to improving the color, bendability, and / or corrosion resistance of the surface of the metal substrate. When applied to products such as direct chill or continuous cast products, the cold spray coating may increase productivity by avoiding or minimizing facing finishes, improving near surface microstructure, and / or improving final gauge properties. Various other benefits and advantages may be realized by the systems and methods provided herein, and the above-mentioned advantages should not be considered limiting.

[0014] 1-4 illustrate an example of a metal processing system 100 for processing a metal substrate 102, according to various embodiments, that includes a cold spray system 104. In certain embodiments, in addition to the cold spray system 104, the metal processing system 100 may include one or more additional systems or equipment 142 for further processing the metal substrate 102, as described in more detail below.

[0015] As illustrated in FIG. 1, the metal substrate 102 includes opposing surfaces 106, 108 and, in the embodiment of FIG. 1, is processed in a processing (or casting) direction 110. The metal substrate 102 may be a variety of materials, including, but not limited to, aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composites, sheets used in composites, or any other suitable metal, non-metal, or combination of materials. Monolithic materials, as well as non-monolithic materials, such as roll-bonded materials, clad alloys, clad layers, composites (such as, but not limited to, carbon fiber-containing materials), or a variety of other materials, may also be useful in the methods and products described herein. In certain embodiments, the metal substrate 102 is an aluminum alloy, such as a 1xxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or an 8xxx series aluminum alloy. In one non-limiting example, the metal substrate 102 is at least one of a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

[0016] As non-limiting examples, exemplary 1xxx alloys for use in the methods and products described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

[0017] Non-limiting examples of 2xxx series alloys for use in the methods and products described herein include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, , AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2 424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA20 29, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

[0018] Non-limiting examples of 3xxx series alloys for use in the methods and products described herein include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA30 AA3025, AA3026, AA3030, AA3130, or AA3065.

[0019] Non-limiting examples of 4xxx series alloys for use in the methods and products described herein may include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0020] Non-limiting examples of 5xxx series alloys for use in the methods and products described herein include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA51 19, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5 049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5 554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A , AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

[0021] Non-limiting examples of 6xxx series alloys for use in the methods and products described herein include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA63 06, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA60 28, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6 261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0022] Non-limiting examples of 7xxx series alloys for use in the methods and products described herein include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA 7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, A A7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7 129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA70 49, AA7049A, AA7149, 7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055 , AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0023] Non-limiting examples of 8xxx series alloys for use in the methods and products described herein include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA802 1, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

[0024] 1 and 2, the metal substrate 102 is a continuous cast metal sheet, however, in other embodiments, the metal substrate 102 may be other types of substrates as desired, including, but not limited to, ingots, billets, other cast products, plates, shates, sheets, and / or other rolled products, as desired. In one non-limiting example, the metal substrate 102 is an ingot formed by direct chill casting.

[0025] Generally, the cold spray system 104 includes a nozzle 112 for depositing particles 114 that form a cold spray coating 116 (see FIG. 2 ) having a thickness 122 on at least one surface of the metal substrate 102. In the illustrated embodiment, the cold spray system 104 deposits the particles 114 on the surface 106 such that the cold spray coating 116 is on the surface 106, although in other embodiments, the cold spray system 104 may deposit the particles 114 on the surface 108, or on both surfaces 106, 108, as desired. The cold spray system 104 may also include a particle (or powder) feeder 118 for receiving a supply of the particles 114, and a heater 120 for heating a gas used to accelerate the particles 114 on the metal substrate 102.

[0026] The particle feeder 118 may receive a supply of particles 114 and supplies the particles 114 to the nozzle 112. In certain embodiments, the particle feeder 118 may be controlled to control the rate at which the particles 114 are fed to the nozzle 112, thereby controlling the rate at which the particles 114 are cold sprayed onto the metal substrate 102 and the thickness 122 of the cold spray coating 116. The particles 114 may be various types of powder materials suitable for cold spraying as desired, and in certain embodiments, the particles 114 are metals, including but not limited to aluminum alloys. In one non-limiting example, the particles 114 are 6xxx series aluminum alloys. In one non-limiting example, at least one characteristic or property of the metal used as the particles 114 may be different from the metal of the metal substrate 102. In one non-limiting example, the metal used as the particles 114 may have a hardness that is greater than the hardness of the metal of the metal substrate 102. The particles 114 may have a variety of diameters as desired, and in certain embodiments, the diameter may be from greater than 0 μm to about 100 μm, such as greater than 0 μm to about 50 μm, such as from about 5 μm to about 50 μm. In some embodiments, the type of material used for the particles 114 (e.g., a particular aluminum alloy) and / or the size of the particles 114 may be controlled to control the thickness 122 of the cold spray coating 116.

[0027] The heater 120 can be any suitable device or mechanism for receiving a gas and heating the gas to a desired temperature. The gas can be any type of gas suitable for cold spraying as desired, including but not limited to air, nitrogen, helium, and / or other gases or combinations of gases. In some embodiments, the pressure of the gas can be controlled such that the cold spray system 104 is a high pressure cold spray system or a low pressure cold spray system. In certain embodiments, the heater 120 can be controlled to control the temperature to which the gas is heated.

[0028] The nozzle 112 can be any type of nozzle suitable for spraying the particles 114 onto the metal substrate 102 during the cold spray process. During the cold spray process, the nozzle 112 scans or traverses over the metal substrate 102 to spray the particles 114 onto the metal substrate 102 to form a cold spray coating 116, and the nozzle 112 can include various deposition controls to control the thickness 122 of the cold spray coating 116. The deposition controls of the nozzle 112 can include, but are not limited to, the distance between the nozzle 112 and the metal substrate 102, the transverse direction (e.g., parallel to the casting direction 110 or perpendicular to the casting direction 110), the linear velocity, the number of passes over a given area on the metal substrate 102, and / or the scan step (the distance between adjacent passes).

[0029] During the cold spray process, a particle feeder 118 supplies particles 114 to the nozzle 112, which in turn supplies heated gas from a heater 120 to accelerate the particles 114 to a high velocity, which then sprays onto the metal substrate 102. Upon impact with the metal substrate 102, the particles 114 undergo adiabatic heating and plastically deform to mechanically adhere to the metal substrate 102, forming a cold spray coating 116. In certain embodiments, the metal substrate 102 may be optionally heated prior to the cold spray process, as described in more detail below, and the heated metal substrate 102 may be cold sprayed to create an interface that is both mechanically and chemically bonded.

[0030] As discussed above, one or more control parameters of the cold spray system 104 can be controlled such that the cold spray coating 116 has a thickness 122 that covers exudates and / or other imperfections on the surface of the metal substrate 102. The thickness 122 shown in FIG. 2 is exaggerated for ease of viewing and is not intended to infer a particular thickness 122 for the metal substrate 102. In one non-limiting example, the cold spray system 104 can be controlled such that the thickness 122 of the cold spray coating 116 is between about 20 μm and about 300 μm, such as between about 30 μm and about 200 μm, such as between about 30 μm and about 150 μm, such as between about 30 μm and about 100 μm, or such as between about 60 μm and about 100 μm. In some embodiments, the cold spray system 104 is controlled such that the thickness 122 of the cold spray coating 116 is less than the thickness of the metal substrate 102. Non-limiting examples of parameters of the cold spray system 104 that may be controlled during processing include, but are not limited to, the type of gas used to accelerate the particles 114, the gas pressure used to accelerate the particles, the temperature to which the heater 120 heats the gas, the type of material used as the particles 114, the diameter or size of the particles 114, the feed rate of the particles 114 from the particle feeder 118, the type of nozzle 112, the angle of the nozzle 112 with respect to the surface of the metal substrate 102, the distance between the nozzle 112 and the metal substrate 102, the linear velocity of the nozzle 112 over the metal substrate 102, the transverse direction of the nozzle 112 over the metal substrate 102, the number of passes of the nozzle 112, and / or the scan step.

[0031] 3 and 4 show two non-limiting examples of patterns for cold spraying particles 114 onto a metal substrate 102 using a cold spray system 104 to form a cold spray coating 116 on a surface 106. FIG. 3 shows a first spray path 124A of the nozzle 112, and FIG. 4 shows a second spray path 124B of the nozzle 112. In FIG. 3, the first spray path 124A is in a transverse direction (or short direction 126 along the surface 106) perpendicular to the casting direction 110, and the scan step 128 is a first distance (e.g., 1 mm). In FIG. 4, the second spray path 124B is parallel to the casting direction 110, and the scan step 128 is a second distance (e.g., 3 mm) greater than the first distance. Various other spray patterns and / or spray paths may be utilized by the cold spray system 104 as needed to provide a cold spray coating 116 having a desired thickness 122.

[0032] 1, in certain embodiments, in addition to the cold spray system 104, the metal processing system 100 optionally includes at least one additional processing equipment 142. In the illustrated embodiment, the additional processing equipment 142 is a rolling mill workstand 130, although in other embodiments, additional types of processing equipment may be utilized with the metal processing system 100 as needed. Non-limiting examples of processing equipment may include, but are not limited to, equipment for casting the metal substrate 102, equipment for homogenizing, equipment for hot rolling, equipment for cold rolling, equipment for solution heat treating, equipment for aging, equipment for coil forming, equipment for shearing, equipment for stamping, equipment for forming, and / or equipment for roll forming. Additionally, while the equipment 142 is shown as being downstream from the cold spray system 104 in the casting direction 110, in other embodiments this need not be the case, and in some optional embodiments, the cold spray system 104 may be located between two pieces of equipment 142. As a non-limiting example, the cold spray system 104 may be provided immediately downstream from a heater or furnace as the first equipment 142 and immediately upstream from a rolling mill workstand as the second equipment. In certain embodiments, the cold spray system 104 may be in various locations relative to other equipment such that the cold spray system 104 deposits particles 114 for the cold spray coating 116 on the metal substrate 102, yet the metal substrate 102 is warmed from an upstream process. In such embodiments, the metal substrate 102 does not need to be heated by a separate heater. In other words, the metal substrate 102 may be a warmed, heated, or hot material suitable for forming the cold spray coating 116 by heating and / or by utilizing residual heat from an upstream process operation. Non-limiting examples of such upstream process operations may include, but are not limited to, casting, warm or hot rolling, interannealing, continuous annealing solution heat treatment, combinations thereof, and / or other upstream process operations as needed.

[0033] Figures 5 and 6 show two metal processing operations in which cold spraying with cold spray system 104 is performed in conjunction with at least one additional metal processing technique. Figure 5 shows a non-limiting example of a metal processing operation 500 according to various embodiments that includes cold spraying and rolling, and Figure 6 shows a non-limiting example of a metal processing operation 600 according to embodiments that includes heating and cold spraying.

[0034] 5, in block 501, the process 500 includes receiving a metal substrate 102 and cold spraying the metal substrate 102 using a cold spray system 104 to form a cold spray coating 116 on at least one of the surfaces (e.g., surface 106) of the metal substrate 102. In certain embodiments, block 501 includes controlling the cold spray system 104 to control a thickness 122 of the cold spray coating 116. In such embodiments, block 501 may include controlling the cold spray system 104 such that the cold spray coating 116 includes a thickness 122 sufficient to cover exudates and / or other defects on the surface of the metal substrate 102. In some non-limiting embodiments, controlling the cold spray system 104 includes controlling the cold spray system 104 so that the thickness 122 is between about 20 μm and about 300 μm, such as between about 30 μm and about 200 μm, such as between about 30 μm and about 150 μm, such as between about 30 μm and about 100 μm, or such as between about 60 μm and about 100 μm. Optionally, in block 501, controlling the cold spray system 104 may include, but is not limited to, controlling the type of gas used to accelerate the particles 114, the gas pressure used to accelerate the particles, the temperature to which the heater 120 heats the gas, the type of material used as the particles 114, the diameter or size of the particles 114, the feed rate of the particles 114 from the particle feeder 118, the type of nozzle 112, the angle of the nozzle 112 with respect to the surface of the metal substrate 102, the distance between the nozzle 112 and the metal substrate 102, the linear velocity of the nozzle 112 over the metal substrate 102, the transverse direction of the nozzle 112 over the metal substrate 102, the number of passes of the nozzle 112, and / or the scan step.

[0035] At block 503, the process includes rolling the metal substrate 102 with the cold spray coating 116 using a rolling mill. In one non-limiting embodiment, block 503 can include rolling using a hot rolling mill to form a hot rolled plate, hot rolled shave, or hot rolled sheet with a gauge between 3 mm and 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anything in between). As another non-limiting embodiment, block 503 can include rolling using a cold rolling mill to form a cold rolled sheet having a gauge of between about 0.5-10 mm, such as between about 0.7-6.5 mm. Optionally, the cold rolled product can have a gauge of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm, or 10.0 mm.

[0036] Optionally, the process 500 may include one or more processing steps or techniques prior to cold spraying at block 501 and / or after rolling at block 503. In one non-limiting example, the process may include continuous casting the metal substrate 102 prior to cold spraying, or direct chill casting an ingot as the metal substrate 102 prior to cold spraying. In another non-limiting example, the process may include rolling the metal substrate 102 prior to cold spraying, and / or heating or homogenizing the metal substrate 102 prior to cold spraying.

[0037] In certain embodiments, in addition to masking exudates with the cold spray coating 116, rolling the metal substrate 102 after applying the cold spray coating 116 according to process 500 may improve adhesion between the particles 114 that form the cold spray coating 116, as well as between the particles 114 and the metal substrate 102. Rolling the metal substrate 102 after applying the cold spray coating 116 may also minimize or reduce porosity in the cold spray coating 116, thereby improving the properties of the cold spray coating 116 for subsequent processing and / or as a final product.

[0038] 6, in block 601, the process 600 includes heating the metal substrate 102 and / or receiving the heated metal substrate 102. In block 601, heating the metal substrate 102 and / or receiving the heated metal substrate 102 may include using residual heat from an upstream process operation or equipment (and / or receiving the metal substrate 102 heated from residual heat from an upstream process operation) and / or heating the metal substrate 102 in block 601 may include heating the metal substrate using a heater. As non-limiting examples, upstream processes such as casting, rolling, and / or continuous annealing solution heat treatment may provide the metal substrate 102 with residual heat suitable for heating the metal substrate 102 for cold spraying. Additionally or alternatively, a dedicated heater or heating system may heat the metal substrate 102 prior to cold spraying. In one non-limiting example, heating the metal substrate 102 includes heating the metal substrate 102 to a temperature in the range of about 400°C to about 500°C, e.g., about 400°C, about 410°C, about 420°C, about 430°C, about 440°C, about 450°C, about 460°C, about 470°C, about 480°C, about 490°C, or about 500°C. In another non-limiting example, heating the metal substrate 102 optionally includes heating the metal substrate 102 such that the temperature of the metal substrate 102 after cold spraying is between about 250°C and about 400°C, e.g., about 250°C, about 260°C, about 270°C, about 280°C, about 290°C, about 300°C, about 310°C, about 320°C, about 330°C, about 340°C, about 350°C, about 360°C, about 370°C, about 380°C, about 390°C, or about 400°C.

[0039] After the heating performed in block 601, process 600 includes cold spraying the heated metal substrate 102 in block 603. Block 603 is substantially similar to block 501 of process 500. Similar to process 500, process 600 optionally includes one or more additional processing steps before block 601 and / or after block 604.

[0040] In certain embodiments, in addition to hiding exudates with the cold spray coating 116, heating the metal substrate 102 prior to applying the cold spray coating 116 according to process 600 may create a chemical and / or mechanical bond interface between the cold spray coating 116 and the metal substrate 102. Such an interface with chemical and mechanical bonds may provide improved protection to the metal substrate 102 during use (e.g., as an end product).

[0041] 7 and 8 are enlarged images showing an AA6111 alloy metal substrate 702 having a cold spray coating 716 formed by AA6061 alloy particles 714. FIG. 7 shows the metal substrate 702 with the cold spray coating 716 before rolling, and FIG. 8 shows the metal substrate 702 with the cold spray coating 716 after rolling and heat treatment. As shown in FIG. 7, without rolling, the cold spray coating 716 may include porosity 734 of various sizes between the particles 714 forming the cold spray coating 716. By comparison, as shown in FIG. 8, rolling and heat treating the metal substrate 702 with the cold spray coating 716 may eliminate or substantially eliminate such porosity 734, thereby improving the properties of the cold spray coating 716.

[0042] 9-19 are images and charts illustrating the properties of metal substrates with cold spray coatings according to the methods described herein. In these examples, Samples 1-4 (abbreviated herein as "S1", "S2", "S3", and "S4", respectively) each included a continuously cast AA6111 alloy metal substrate 902 and a cold spray coating formed of AA6061 alloy particles on one side of the metal substrate 902. The opposite side of the metal substrate 902 was not cold sprayed. Each of S1-4 was also heated such that the temperature of the metal substrate prior to cold spraying was between 420°C and 500°C. The control substrate 938 (hereinafter "control") in these examples was an as-cast AA6111 alloy metal substrate.

[0043] In S1, the cold spray coating 916A was applied to the metal substrate 902 by moving the nozzle of the cold spray system in a direction perpendicular to the casting direction at a linear speed of 750 mm / s, a scan step of 1 mm, and a particle feeder speed of 1 RPM. FIG. 9 shows the cold spray coating 916A on the metal substrate 902 and before any rolling. In this embodiment, the thickness 122 of the cold spray coating 916A ranged from 18 μm to 43 μm, with an average thickness of 33 μm.

[0044] In S2, the cold spray coating 916B was applied to the metal substrate 902 by moving the nozzle of the cold spray system in a direction perpendicular to the casting direction at a linear speed of 250 mm / s, a scan step of 1 mm, and a particle feeder speed of 1.4 RPM. FIG. 10 shows the cold spray coating 916B on the metal substrate 902 and before any rolling. In this embodiment, the thickness 122 of the cold spray coating 916B ranged from 72 μm to 172 μm, with an average thickness of 126 μm.

[0045] In S3, the cold spray coating 916C was applied to the metal substrate 902 by moving the nozzle of the cold spray system in a direction parallel to the casting direction at a linear speed of 250 mm / s, a scan step of 1 mm, and a particle feeder speed of 1.4 RPM. FIG. 11 shows the cold spray coating 916C on the metal substrate 902 and before any rolling. In this embodiment, the thickness 122 of the cold spray coating 916C ranged from 87 μm to 203 μm, with an average thickness of 149 μm.

[0046] In S4, the cold spray coating 916D was applied to the metal substrate 902 by moving the nozzle of the cold spray system in a direction parallel to the casting direction at a linear speed of 150 mm / s, a scan step of 3 mm, and a particle feeder speed of 4 RPM. FIG. 12 shows the cold spray coating 916D on the metal substrate 902 and before any rolling. In this embodiment, the thickness 122 of the cold spray coating 916D ranged from 120 μm to 293 μm, with an average thickness of 200 μm.

[0047] As shown by comparing Figures 9-12, the cold spray system controlled according to S1 produced the thinnest cold spray coating 916A having a thickness of 122, while the cold spray system controlled according to S4 produced the thickest cold spray coating 916D.

[0048] 13 shows S3 after rolling. As shown in this figure, the exudates 936 at the interface between the cold spray coating 916C and the metal substrate 902 have been covered and hidden by the cold spray coating 916C. Without the cold spray coating 916, the exudates 936 would have been present on the exterior surface of the metal substrate 902 and would have required removal and / or limited the use of the metal substrate 902 to interior or structural applications.

[0049] FIG. 14 is a chart showing the surface roughness (Sa) after rolling of S1-4 compared to the control. Surface roughness was measured on both the cold sprayed and non-cold sprayed sides for each of S1-4 and the control. S1-S4 and the control were also tested for material strength and elongation according to ASTM B557, and the cold spray coatings of S1-S4 showed no significant effect on material strength or elongation. Such results indicate that the cold spray coating did not degrade the properties of the metal substrate.

[0050] In certain embodiments, in addition to masking exudates and preserving some properties of the metal substrate, cold spray coatings may improve the properties of the metal substrate that they are coated on, as shown in Figures 9-14. As some non-limiting examples, cold spray coatings may improve bendability, corrosion performance (e.g., corrosion resistance), and / or color quality.

[0051] As a non-limiting example, the cold spray coatings described herein may be used on 5xxx series aluminum alloys, including but not limited to 5182 aluminum alloy, to improve surface color change due to magnesium oxide formation after heat treatment or hot rolling of such alloys.

[0052] As another non-limiting example, Figure 15 shows the bend angle of S1-4 and the control after rolling when tested according to VDA-238-100. As shown in Figure 15, S1 (minimum thickness cold spray coating) and S2 (medium thickness cold spray coating applied perpendicular to the casting direction) both improved bend performance compared to the control.

[0053] As a further non-limiting example, Figures 16-19 are top view images showing the intergranular corrosion performance after 24 hours of exposure of the control to a chemical (Figure 16), 24 hours of exposure of S2 to the same chemical (Figure 17), 48 hours of exposure of the control to the same chemical (Figure 18), and 48 hours of exposure of S2 to the same chemical (Figure 19). Figures 16 and 18 show the intergranular corrosion 940 in the control after both 24 and 48 hours. In comparison, the area of ​​intergranular corrosion 940 was significantly reduced in S2, indicating that the cold spray coating improved corrosion resistance compared to the substrate without the cold spray coating.

[0054] 20A-C are partial images of a metal substrate with a cold spray coating according to an embodiment, showing the good adhesion achieved between the substrate and the cold spray coating. Each of FIGS. 20A-C shows the metal substrate after the same rolling operation. FIG. 20A shows a 5xxx aluminum alloy substrate 2002A with a cold spray coating 2016A formed with AA6061 alloy particles. FIG. 20B shows a 6xxx aluminum alloy substrate 2002A with a cold spray coating 2016A formed with AA6061 alloy particles. FIG. 20C shows a 7xxx aluminum alloy substrate 2002A with a cold spray coating 2016A formed with AA6061 alloy particles. In FIG. 20A, the cold spray coating 2016A had a thickness of about 30 μm. In FIG. 20B, the cold spray coating 2016B had a thickness of about 45 μm. In FIG. 20C, the cold spray coating 2016C had a thickness of about 40 μm.

[0055] FIG. 21 shows an example of a metal substrate 2102A with a cold spray coating according to an embodiment compared to a metal substrate 2102B without a cold spray coating. In FIG. 21, both metal substrates 2102A-B are the same 5xxx aluminum alloy, and the metal substrate 2102A further included a cold spray coating formed of 6xxx aluminum particles. As shown by comparing the metal substrate 2102A to the metal substrate 2102B, the metal substrate 2102A with the cold spray coating had a visually brighter appearance compared to the metal substrate 2102B without the cold spray coating.

[0056] FIG. 22 shows an example of a metal substrate 2202A with a cold spray coating according to an embodiment compared to a metal substrate 2202B without a cold spray coating. In FIG. 22, both metal substrates 2202A-B are the same 7xxx aluminum alloy, and metal substrate 2202A further included a cold spray coating formed of 6xxx aluminum particles. As shown by comparing metal substrate 2202A to metal substrate 2202B, metal substrate 2102A with a cold spray coating had a visually brighter appearance compared to metal substrate 2102B without a cold spray coating.

[0057] 23A-B show the corrosion of a metal substrate 2302A with a cold spray coating according to an embodiment compared to the corrosion of a metal substrate 2302B without a cold spray coating. In FIG. 23A-B, both metal substrates 2302A-B are the same 7xxx aluminum alloy, and metal substrate 2302A further included a cold spray coating formed of 6xxx aluminum particles. Corrosion testing was performed on both metal substrates 2302A-B using ISO 11846B testing. As shown by comparing metal substrates 2302A-B, metal substrate 2302B (without cold spray coating) generally suffered corrosion 2340, while metal substrate 2302A (with cold spray coating) generally did not.

[0058] Various other benefits and advantages may be realized by the techniques described herein, and the above mentioned advantages should not be considered limiting.

[0059] As mentioned above, the metal products with cold spray coatings described herein can be used in a variety of products, and can be particularly useful for Class A products. In some examples, the metal products can be used in transportation applications, such as automotive applications, as well as other aircraft and railroad applications, or any other desired application. For example, the metal products of the present disclosure with cold spray coatings can be used to fabricate automotive structural components, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The metal products and methods with cold spray coatings described herein can also be used in aircraft or railroad applications, for example, to fabricate exterior and interior panels.

[0060] The metal products with cold spray coatings and methods described herein can also be used in electronics applications. For example, the metal products with cold spray coatings and methods described herein can be used to fabricate housings for electronic devices, including mobile phones and tablet computers. In some examples, the metal products with cold spray coatings can be used to fabricate outer casings for mobile phones (e.g., smartphones), tablet bottom chassis, and housings for other portable electronic devices.

[0061] Example Provided below is a collection of exemplary embodiments, including at least some explicitly listed as "exemplary," that provide further explanation of various exemplary embodiments according to the concepts described herein. These examples are not intended to be mutually exclusive, exhaustive, or limiting, and the present disclosure is not limited to these example illustrations, but rather encompasses all feasible modifications and variations within the scope of the issued claims and their equivalents.

[0062] Example 1. A method for processing a metal substrate, comprising additively depositing metal particles by cold spraying the metal particles onto the metal substrate to produce a cold spray coating adhered to the metal substrate, and rolling the metal substrate with the cold spray coating in a rolling mill.

[0063] Example 2. The method of any preceding or following example or combination of examples, wherein the metal substrate comprises a continuous cast metal product, or an ingot formed from a direct chill casting process.

[0064] Example 3. The method of any preceding or following example or combination of examples, wherein additively depositing the metal particles to produce the cold spray coating includes controlling the deposition of the metal particles such that the cold spray coating has a thickness of 30 to 200 μm, inclusive.

[0065] Example 4. The method of any preceding or following example or combination of examples, wherein controlling the deposition of the metal particles includes controlling the deposition of the metal particles such that the thickness is between 60 and 100 μm, inclusive.

[0066] Example 5. The method of any preceding or subsequent example or combination of examples, wherein additively depositing the metal particles to produce the cold spray coating includes additively depositing the metal particles in a direction perpendicular to a casting direction of the metal substrate.

[0067] Example 6. The method of any preceding or following example or combination of examples, further comprising heating the metal substrate prior to cold spraying the metal substrate.

[0068] Example 7. The method of any preceding or following example or combination of examples, wherein heating the metal substrate includes at least one of heating the metal substrate using residual heat from an upstream process operation or heating the metal substrate with a dedicated heater.

[0069] Example 8. The method of any preceding or following example or combination of examples, wherein the metal substrate comprises at least one of a 5xxx series aluminum alloy metal substrate, a 6xxx series aluminum alloy metal substrate, or a 7xxx series aluminum alloy metal substrate, and the metal particles of the cold spray coating comprise at least one of a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

[0070] Example 9. The method of any preceding or following example or combination of examples, wherein depositing the metal particles on the metal substrate to produce the cold spray coating includes controlling the deposition of the metal such that a thickness of the cold spray coating is less than a thickness of the metal substrate.

[0071] Example 10. A method of processing a metal substrate, comprising: rolling the metal substrate using a rolling mill; and additively depositing metal particles by cold spraying the metal particles onto the rolled metal substrate to produce a cold spray coating adhered to the rolled metal substrate.

[0072] Example 11. The method of any preceding or following example or combination of examples, wherein rolling the metal substrate comprises hot rolling the metal substrate.

[0073] Example 12. The method of any preceding or following example or combination of examples, wherein additively depositing the metal particles to produce the cold spray coating includes controlling the deposition of the metal particles such that the cold spray coating has a thickness of 30 to 200 μm, inclusive.

[0074] Example 13. The method of any preceding or following example, or combination of examples, wherein controlling the deposition of the metal particles includes controlling the deposition of the metal particles such that the thickness is between 60 and 100 μm, inclusive.

[0075] Example 14. The method of any preceding or subsequent example or combination of examples, wherein additively depositing the metal particles to produce the cold spray coating includes additively depositing the metal particles across the metal substrate in a direction perpendicular to a casting direction of the metal substrate.

[0076] Example 15. The method of any preceding or following example or combination of examples, wherein the metal substrate comprises at least one of a 5xxx series aluminum alloy metal substrate, a 6xxx series aluminum alloy metal substrate, or a 7xxx series aluminum alloy metal substrate, and the metal particles of the cold spray coating comprise a 6xxx series aluminum alloy.

[0077] Example 16. The method of any preceding or subsequent example or combination of examples, wherein depositing the metal particles on the metal substrate to produce the cold spray coating includes controlling the deposition of the metal particles such that a thickness of the cold spray coating is less than a thickness of the metal substrate.

[0078] Example 17. The method of any preceding or following example or combination of examples, further comprising heating the metal substrate prior to cold spraying, wherein heating the metal substrate comprises at least one of heating the metal substrate using residual heat from an upstream process operation or heating the metal substrate with a dedicated heater.

[0079] Example 18. A method for processing a metal substrate, comprising: receiving the metal substrate in a cold spray system, the metal substrate being a heated metal substrate; and additively depositing metal particles by cold spraying the metal particles onto the metal substrate to produce a cold spray coating adhered to the metal substrate.

[0080] Example 19. The method of any preceding or following example, or combination of examples, wherein receiving the metal substrate comprises receiving a continuously cast metal substrate, or an ingot formed by direct chill casting.

[0081] Example 20. A method according to any preceding or subsequent example or combination of examples, wherein additively depositing the metal particles to produce the cold spray coating includes additively depositing the metal particles across a width of the metal substrate and controlling the deposition of the metal particles such that a thickness of the cold spray coating is less than a thickness of the metal substrate.

[0082] Example 21. The method of any preceding or following example or combination of examples, wherein additively depositing the metal particles to produce the cold spray coating includes controlling the deposition of the metal particles such that the cold spray coating has a thickness of 30 to 200 μm, inclusive.

[0083] Example 22. The method of any preceding or subsequent example or combination of examples, further comprising heating the metal substrate prior to receiving the metal substrate in the cold spray system.

[0084] Example 23. The method of any preceding or following example or combination of examples, wherein prior to additively depositing the metal particles, the metal substrate is heated using at least one of residual heat from an upstream process operation for heating the metal substrate or a dedicated heater for heating the metal substrate.

[0085] Example 24. A metal processing system including a cold spray system configured to additively deposit metal particles by cold spraying the metal particles onto a metal substrate to produce a cold spray coating adhered to the metal substrate, and a rolling mill downstream from the cold spray system and configured to roll the metal substrate having the cold spray coating.

[0086] Example 25. The metal processing system of any preceding or following example or combination of examples, further comprising a continuous casting apparatus upstream from the cold spray system and configured to cast the metal substrate.

[0087] Example 26. The metal processing system of any preceding or following example or combination of examples, wherein the rolling mill is a hot rolling mill.

[0088] Example 27. The metal processing system of any preceding or subsequent example or combination of examples, wherein the cold spray system is configured to additively deposit the metal particles on the metal substrate across a width of the metal substrate.

[0089] Example 28. The metal processing system of any preceding or subsequent example, or combination of examples, further comprising a controller configured to control the cold spray system such that the thickness of the cold spray coating is between 30 and 200 μm, inclusive.

[0090] Example 29. A metal processing system as described in any preceding or subsequent example or combination of examples, wherein the controller is configured to control the cold spray system by controlling at least one of a linear velocity of a nozzle of the cold spray system or a powder feed rate of the metal particles deposited as the cold spray coating.

[0091] Example 30. A metal processing system including a cold spray system configured to additively deposit metal particles by cold spraying the metal particles onto a metal substrate to produce a cold spray coating adhered to the metal substrate, and a rolling mill upstream from the cold spray system and configured to roll the metal substrate prior to the deposition of the metal particles by the cold spray system.

[0092] Example 31. The metal processing system of any preceding or subsequent example, or combination of examples, further comprising a controller configured to control the cold spray system such that the thickness of the cold spray coating is between 30 and 200 μm, inclusive.

[0093] Example 32. A metal processing system as described in any preceding or subsequent example or combination of examples, wherein the controller is configured to control the cold spray system by controlling at least one of a linear velocity of a nozzle of the cold spray system or a powder feed rate of the metal particles deposited as the cold spray coating.

[0094] Example 33. A metal processing system including a cold spray system configured to receive a heated metal substrate, the cold spray system configured to additively deposit metal particles by cold spraying the metal particles onto the heated metal substrate to produce a cold spray coating adhered to the metal substrate.

[0095] Example 34. The metal processing system of any preceding or subsequent example or combination of examples, further comprising a rolling mill downstream from the cold spray system and configured to roll the metal substrate having the cold spray coating.

[0096] Example 35. The metal processing system of any preceding or subsequent example, or combination of examples, wherein the cold spray system is configured to additively deposit the metal particles on the metal substrate across a width of the metal substrate.

[0097] Example 36. The metal processing system of any preceding or subsequent example, or combination of examples, further comprising a controller configured to control the cold spray system such that the thickness of the cold spray coating is between 30 and 200 μm, inclusive.

[0098] Example 37. A metal processing system as described in any preceding or subsequent example or combination of examples, wherein the controller is configured to control the cold spray system by controlling at least one of a linear velocity of a nozzle of the cold spray system or a powder feed rate of the metal particles deposited as the cold spray coating.

[0099] Example 38. The metal processing system of any preceding or subsequent example, or combination of examples, wherein the cold spray system is configured to receive the metal substrate at a temperature in the range of about 400°C to about 500°C.

[0100] Example 39. The metal processing system of any preceding or subsequent example or combination of examples, further comprising at least one device upstream from the cold spray system and configured to provide at least residual heat to the metal substrate.

[0101] Example 40. The metal processing system of any preceding or following example or combination of examples, wherein the at least one piece of equipment includes at least one of a casting apparatus, a warm or hot rolling mill, a continuous annealing solution heat treatment system, or a heater.

[0102] Example 41. A metal product formed by the method of any of the preceding or following examples or combinations of examples.

[0103] Although the subject matter of the embodiments has been described herein with specificity to meet statutory requirements, this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be construed as implying a particular order or arrangement between the various steps or elements, unless the order of the individual steps or arrangement of the elements is explicitly described. References to directions such as "upper", "lower", "top", "bottom", "left", "right", "front", and "rear" are intended to refer, inter alia, to the orientations illustrated and described in the figure (or figures) to which the components and directions refer. Throughout this disclosure, reference numerals accompanied by letters refer to particular specific examples of elements, while reference numerals without accompanying letters refer to elements generally or collectively. Thus, as an example (not shown), device "12A" refers to a specific example of a family of devices, any one of which may be collectively referred to as device "12." In the drawings and the description, like numerals are intended to represent like elements. As used herein, the meanings of "a," "an," and "the" include singular and plural references unless the context clearly dictates otherwise.

[0104] References are made herein to alloys identified by AA numbers and other related designations, such as "series" or "7xxx." For an understanding of the numbering systems most commonly used to name and identify aluminum and its alloys, see "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot" (both published by the Aluminum Association).

[0105] As used herein, plate generally has a thickness of greater than about 15 mm. For example, plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0106] As used herein, a shade (also referred to as a sheet plate) generally has a thickness of about 4 mm to about 15 mm. For example, the shade may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0107] As used herein, sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, the sheet can have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm, (e.g., about 0.2 mm).

[0108] As used herein, the terms "cast metal product," "cast product," "cast aluminum alloy product," and the like are used interchangeably and refer to products produced by vertical semi-continuous casting (including vertical semi-continuous simultaneous casting), semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, twin roll caster, block caster, or any other continuous casting machine), electromagnetic casting, hot top casting, or any other casting process.

[0109] All ranges disclosed herein should be understood to include any and all subranges subsumed therein. For example, a range described as "1-10" should be considered to include any and all subranges between the minimum value of 1 and the maximum value of 10, inclusive. That is, all subranges begin with a minimum value of 1 or more, e.g., 1-6.1, and end with a maximum value of 10 or less, e.g., 5.5-10. Unless otherwise indicated, the term "maximum" when referring to a compositional amount of an element means that the element is optional and includes a zero percent composition of that particular element. Unless otherwise indicated, all compositional percentages are weight percent (wt.%).

[0110] The above-mentioned aspects are merely possible examples of implementations and are described merely for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-mentioned embodiment(s) without substantially departing from the spirit and principles of the present disclosure. All such modifications and modifications are intended to be included herein within the scope of the present disclosure, and all possible claims directed to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are used in the present specification and the following claims, they are used in a generic and descriptive sense only and not for the purpose of limiting the described embodiments, nor the scope of the following claims.

Claims

1. 1. A method for processing a metal substrate, comprising: additively depositing metal particles by cold spraying the metal particles onto the metal substrate to produce a cold spray coating adhered to the metal substrate; rolling the metal substrate having the cold spray coating using a rolling machine; The method comprising:

2. The method of claim 1 , wherein the metal substrate comprises a continuous cast metal product or an ingot formed from a direct chill casting process.

3. 2. The method of claim 1 , wherein additively depositing the metal particles to produce the cold spray coating comprises controlling the deposition of the metal particles such that the cold spray coating has a thickness of 30 to 200 μm, inclusive.

4. The method of claim 3, wherein controlling the deposition of the metal particles comprises controlling the deposition of the metal particles such that the thickness is between 60 and 100 μm, inclusive.

5. The method of claim 1 , wherein additively depositing the metal particles to create the cold spray coating comprises additively depositing the metal particles in a direction perpendicular to a casting direction of the metal substrate.

6. The method of claim 1 further comprising heating the metal substrate prior to cold spraying the metal substrate.

7. Heating the metal substrate comprises: Heating the metal substrate using residual heat from an upstream process operation; or Heating the metal substrate using a dedicated heater; The method of claim 6 , comprising at least one of:

8. 10. The method of claim 1, wherein the metal substrate comprises at least one of a 5xxx series aluminum alloy metal substrate, a 6xxx series aluminum alloy metal substrate, or a 7xxx series aluminum alloy metal substrate, and the metal particles of the cold spray coating comprise at least one of a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

9. 2. The method of claim 1, wherein depositing the metal particles on the metal substrate to produce the cold spray coating comprises controlling the deposition of the metal such that a thickness of the cold spray coating is less than a thickness of the metal substrate.

10. 1. A method for processing a metal substrate, comprising: rolling the metal substrate using a rolling machine; additively depositing metal particles by cold spraying the metal particles onto the rolled metal substrate to produce a cold spray coating adhered to the rolled metal substrate; The method comprising:

11. The method of claim 10 , wherein rolling the metal substrate comprises hot rolling the metal substrate.

12. 11. The method of claim 10, wherein additively depositing the metal particles to produce the cold spray coating comprises controlling the deposition of the metal particles such that the cold spray coating has a thickness of 30 to 200 μm, inclusive.

13. The method of claim 12, wherein controlling the deposition of the metal particles comprises controlling the deposition of the metal particles such that the thickness is between 60 and 100 μm inclusive.

14. 11. The method of claim 10, wherein additively depositing the metal particles to create the cold spray coating comprises additively depositing the metal particles across the metal substrate in a direction perpendicular to a casting direction of the metal substrate.

15. 11. The method of claim 10, wherein the metal substrate comprises at least one of a 5xxx series aluminum alloy metal substrate, a 6xxx series aluminum alloy metal substrate, or a 7xxx series aluminum alloy metal substrate, and the metal particles of the cold spray coating comprise a 6xxx series aluminum alloy.

16. 11. The method of claim 10, wherein depositing the metal particles on the metal substrate to produce the cold spray coating comprises controlling the deposition of the metal particles such that a thickness of the cold spray coating is less than a thickness of the metal substrate.

17. further comprising heating the metal substrate prior to cold spraying; Heating the metal substrate comprises: Heating the metal substrate using residual heat from an upstream process operation; or Heating the metal substrate using a dedicated heater; The method of claim 10, comprising at least one of:

18. 1. A method for processing a metal substrate, comprising: receiving the metal substrate in a cold spray system, the metal substrate being a heated metal substrate; additively depositing metal particles by cold spraying the metal particles onto the metal substrate to produce a cold spray coating adhered to the metal substrate; The method comprising:

19. 20. The method of claim 18, wherein receiving the metal substrate comprises receiving a continuous cast metal substrate or an ingot formed by direct chill casting.

20. 20. The method of claim 18, wherein additively depositing the metal particles to create the cold spray coating comprises additively depositing the metal particles across a width of the metal substrate and controlling the deposition of the metal particles such that a thickness of the cold spray coating is less than a thickness of the metal substrate.

21. 20. The method of claim 18, wherein additively depositing the metal particles to produce the cold spray coating comprises controlling the deposition of the metal particles such that the cold spray coating has a thickness of 30 to 200 μm, inclusive.

22. The method of claim 18 , further comprising heating the metal substrate prior to receiving the metal substrate in the cold spray system.

23. 20. The method of claim 18, wherein prior to additively depositing the metal particles, the metal substrate is heated using at least one of residual heat from an upstream process operation to heat the metal substrate or a dedicated heater to heat the metal substrate.

24. a cold spray system configured to additively deposit metal particles by cold spraying the metal particles onto a metal substrate to produce a cold spray coating adhered to the metal substrate; a rolling mill downstream from the cold spray system and configured to roll the metal substrate having the cold spray coating; 4. A metal processing system comprising:

25. 25. The metal processing system of claim 24, further comprising a continuous casting apparatus upstream from the cold spray system and configured to cast the metal substrate.

26. 25. The metal processing system of claim 24, wherein the rolling mill is a hot rolling mill.

27. 25. The metal processing system of claim 24, wherein the cold spray system is configured to additively deposit the metal particles onto the metal substrate across a width of the metal substrate.

28. The metal processing system of claim 24, further comprising a controller configured to control the cold spray system such that the cold spray coating has a thickness between 30 and 200 μm, inclusive.

29. 30. The metal processing system of claim 28, wherein the controller is configured to control the cold spray system by controlling at least one of a linear velocity of a nozzle of the cold spray system or a powder feed rate of the metal particles deposited as the cold spray coating.

30. a cold spray system configured to additively deposit metal particles by cold spraying the metal particles onto a metal substrate to produce a cold spray coating adhered to the metal substrate; a rolling mill upstream from the cold spray system and configured to roll the metal substrate prior to the deposition of the metal particles by the cold spray system; 4. A metal processing system comprising:

31. The metal processing system of claim 30, further comprising a controller configured to control the cold spray system such that the cold spray coating has a thickness between 30 and 200 μm, inclusive.

32. 32. The metal processing system of claim 31 , wherein the controller is configured to control the cold spray system by controlling at least one of a linear velocity of a nozzle of the cold spray system or a powder feed rate of the metal particles deposited as the cold spray coating.

33. 1. A metal processing system comprising: a cold spray system configured to receive a heated metal substrate, the cold spray system configured to additively deposit metal particles by cold spraying the metal particles onto the heated metal substrate to produce a cold spray coating adhered to the metal substrate.

34. 34. The metal processing system of claim 33, further comprising a rolling mill downstream from the cold spray system and configured to roll the metal substrate having the cold spray coating.

35. 34. The metal processing system of claim 33, wherein the cold spray system is configured to additively deposit the metal particles onto the metal substrate across a width of the metal substrate.

36. 34. The metal processing system of claim 33, further comprising a controller configured to control the cold spray system such that the cold spray coating has a thickness between 30 and 200 microns inclusive.

37. 34. The metal processing system of claim 33, wherein the controller is configured to control the cold spray system by controlling at least one of a linear velocity of a nozzle of the cold spray system or a powder feed rate of the metal particles deposited as the cold spray coating.

38. The metal processing system of claim 33, wherein the cold spray system is configured to receive the metal substrate at a temperature in a range of about 400°C to about 500°C.

39. 34. The metal processing system of claim 33, further comprising at least one device upstream from the cold spray system and configured to provide at least residual heat to the metal substrate.

40. 40. The metal working system of claim 39, wherein the at least one piece of equipment comprises at least one of a casting apparatus, a warm or hot rolling mill, a continuous annealing solution heat treatment system, or a heater.

41. 20. A metal product formed by the method of any one of claims 1, 10 or 18.

Images