Method and system for creating a conductive material on a substrate

Abstract

The present invention provides a method and system for creating a conductive material on a substrate. [Solution] A method (100) for creating a conductor (304) on a substrate (302) by cold spraying includes the steps of: propelling a solid powder composition containing copper and highly oriented pyrolysis graphite using a gas propellant (104); and directing the solid powder composition toward the substrate (302) at a speed sufficient to cause the solid powder composition to plastically deform and adhere to the substrate (302) in order to deposit a conductor (304) on the substrate (302).

Description

Technical Field

[0001] The present application relates to a method and system for forming a conductor on a substrate, and to an article formed therefrom.

Background Art

[0002] Most electrical interconnections are formed of about 9 g / cm 3 density made of highly conductive metal such as copper (6×10 7 S / m). It is desirable to replace copper with a material that has a much lower density while providing electrical performance equal to or better than that of copper.

[0003] Accordingly, those skilled in the art continue with research and development in the field of conductor fabrication.

Summary of the Invention

Means for Solving the Problems

[0004] In one example, the disclosed method for forming a conductor on a substrate by cold spraying includes the steps of: heating a gaseous propellant; propelling a solid powder composition comprising copper and highly oriented pyrolytic graphite using the heated gaseous propellant; and directing the solid powder composition toward the substrate at a velocity sufficient to plastically deform the solid powder composition and adhere it to the substrate to deposit the conductor on the substrate.

[0005] In one example, a disclosed system for spraying a coating material onto a substrate includes an optical sensor, a controller, a first regulator, a heater, a second regulator, and an actuator. The optical sensor is positioned to monitor the thickness of the coating material applied to the substrate. The controller communicates with the optical sensor and, based on the measured thickness, generates a first command signal corresponding to the amount of propellant to be heated, a second command signal corresponding to the temperature at which the propellant is heated, a third command signal corresponding to the amount of solid powder composition to be mixed with the heated gas in the nozzle, and a fourth command signal corresponding to the distance between the nozzle and the substrate. The first regulator receives the first command signal and supplies the amount of propellant corresponding to the first command signal. The heater receives the above amount of propellant supplied from the first regulator, receives the second command signal, and heats the propellant to the temperature corresponding to the second command signal. The second regulator receives the third command signal and supplies the amount of solid powder composition corresponding to the third command signal to the nozzle. The actuator receives a fourth command signal and moves the nozzle along the substrate by a distance corresponding to the fourth command signal.

[0006] In one example, the disclosed cold-spray coated product includes a substrate and a conductor deposited on the substrate by cold spraying. The conductor includes a copper matrix and highly oriented pyrolysis graphite plates dispersed in the copper matrix.

[0007] Other examples of the disclosed methods, systems, and products will become apparent from the following detailed description, accompanying drawings, and accompanying claims. [Brief explanation of the drawing]

[0008] [Figure 1] This flowchart shows an example of a disclosed method for creating a conductor on a substrate. [Figure 2] This is a schematic diagram of an example of a disclosed system for spraying a coating material onto a substrate. [Figure 3] This is a perspective view of an example of a cold-spray coated product that has been disclosed. [Figure 4] This is a flowchart illustrating the manufacturing and maintenance procedures for aircraft. [Figure 5] This is a block diagram of an aircraft. [Modes for carrying out the invention]

[0009] Figure 1 is a flowchart illustrating an example of a disclosed method 100 for creating a conductor 304 (Figure 3) on a substrate 302 (Figure 3) by cold spraying. Method 100 includes the steps of: heating a gas propellant 102; using the heated gas propellant to propel a solid powder composition comprising copper and highly oriented pyrolytic graphite (HOPG) 104; and plastically deforming the solid powder composition to deposit the conductor 304 on the substrate 302 and directing the solid powder composition toward the substrate 302 at a speed sufficient to adhere it to the substrate 302. By propelling the solid powder composition in step 104 and directing it toward the substrate 302 in step 106, Method 100 deposits the conductor 304 from copper and highly oriented pyrolytic graphite onto the substrate 302.

[0010] Step 102, which involves heating the gas propellant, facilitates step 104, which involves propelling the solid powder composition to a sufficient speed. When heated, the gas propellant expands, thereby increasing its acceleration and consequently increasing the speed of the solid powder composition. Furthermore, heating the gas propellant also heats the solid powder composition. Heating the solid powder composition facilitates the plastic deformation of the solid powder composition and its adhesion to the substrate 302 (Figure 3), which is necessary for depositing the conductor 304 (Figure 3) onto the substrate 302 (Figure 3).

[0011] The gas propellant heating step 102 can be carried out in any way. In one example, the gas propellant is heated to a suitable temperature by passing it through a heat exchanger. In one example, the gas propellant is heated to a temperature in the range of 450 to 535°C. If the gas propellant is heated above 535°C, the solid powder composition may be adversely affected. In particular, the properties of the highly oriented pyrolysis graphite will deteriorate. Also, the substrate 302 (Figure 3) may deteriorate during the deposition of the conductor 304 (Figure 3) thereon. If the gas propellant is not sufficiently heated below 450°C, a sufficient rate of gas propellant cannot be achieved, the solid powder composition will not plastically deform, and will not adhere to the substrate 302.

[0012] Step 104, in which a solid powder composition containing copper and highly oriented pyrolysis graphite is propelled using a gas propellant, can be carried out in any manner. In one example, the gas propellant is accelerated to a high speed by releasing the gas propellant from a high-pressure state, such as a high-pressure gas state, a liquid state, or a solid state. Before, after, or during the acceleration of the gas propellant, the gas propellant is mixed with the solid powder composition to propel the solid powder composition.

[0013] Step 106, in which the solid powder composition is directed toward the substrate 302 (Figure 3) at a speed sufficient to plastically deform the solid powder composition and adhere it to the substrate 302 in order to deposit the conductor 304 (Figure 3) onto the substrate 302, can be performed in any manner. In one example, the solid powder composition is directed toward the substrate 302 using a nozzle such as a Laval nozzle. Plastic deformation is a process in which permanent deformation occurs in a solid. Plastic deformation results in permanent changes in the solid without fracture as a result of stress exceeding the elastic limit. In this description, the solid powder composition is directed toward the substrate 302 at a speed sufficient to plastically deform the solid powder composition and adhere it to the substrate 302 in order to deposit the conductor 304. By undergoing significant plastic deformation, the solid powder composition adheres to the substrate 302.

[0014] In one example, the solid powder composition is directed towards the substrate 302 at a speed of 500 to 1,000 m / s. If the speed is less than 500 m / s, the solid powder composition may not undergo plastic deformation and may fail to adhere properly to the substrate 302 (Figure 3). If the speed exceeds 1,000 m / s, the substrate 302 may be damaged upon impact.

[0015] According to this disclosure, the solid powder composition comprises copper and highly oriented pyrolysis graphite. The copper may include pure copper, a copper-based alloy, or any alloy containing copper. By selecting the solid powder composition to contain copper, the solid powder composition can undergo plastic deformation upon collision with the substrate 302 (Figure 3) and adhere to the substrate 302. Furthermore, the copper contributes to the high conductivity of the conductor 304 (Figure 3) resulting from deposition on the substrate 302.

[0016] For example, the current density of copper material is approximately 500 amperes per square centimeter (500 A / cm²). 2 This makes it an ideal material for highly conductive matrix materials, particularly in applications such as aircraft maintenance, aircraft repair, and aircraft life monitoring.

[0017] Highly oriented pyrolysis graphite (HOPG) is a very pure, regular form of synthetic graphite. It is characterized by the International Union of Pure and Applied Chemistry (IUPAC) chemical terminology as pyrolysis graphite in which the c-axis angular extent of the microcrystals is less than 1 degree. Highly oriented pyrolysis graphite exhibits high electrical conductivity. By selecting a solid powder composition to contain highly oriented pyrolysis graphite, a conductor 304 deposited on a substrate 302 from the solid powder composition possesses high electrical conductivity.

[0018] For example, highly oriented pyrolytic graphite includes intercalated highly oriented pyrolytic graphite, such as bromine intercalated highly oriented pyrolytic graphite. Due to the layered morphology of graphite, different atomic or molecular species can be inserted between the graphite layers. The process of inserting such dopant species into graphite is called intercalation. Intercalation of highly oriented pyrolytic graphite is effective in altering its properties. Bromine intercalated highly oriented pyrolytic graphite was deemed suitable for inclusion in the solid powder compositions of this disclosure because it maintains stability over long periods.

[0019] In one example, copper particles are present in an amount of 55-65% by weight. If the amount of copper particles is less than 55% by weight, the highly oriented pyrolysis graphite is not completely captured by the copper matrix 306 (Figure 3), and the adhesion of the conductor 304 to the substrate 302 (Figure 3) decreases. If the amount of copper particles is greater than 65% by weight, the overall conductivity of the conductor 304 (Figure 3) decreases, and the weight of the conductor 304 increases.

[0020] In one example, the copper particles have an average particle size in the range of 15 μm to 25 μm. If the average particle size is less than 15 μm, the copper particles cannot adhere to the substrate 302 (Figure 3). If the average particle size is greater than 25 μm, the substrate 302 may be damaged upon impact.

[0021] In one example, multiple plateslets of highly oriented pyrolysis graphite are included in the solid powder composition in an amount of 35-45% by weight. If the plateslets of highly oriented pyrolysis graphite are included in the solid powder composition in an amount of less than 35% by weight, the overall conductivity of the conductor 304 (Figure 3) decreases and the weight of the conductor 304 increases. If the plateslets of highly oriented pyrolysis graphite are included in the solid powder composition in an amount greater than 45% by weight, the adhesion of the conductor 304 to the substrate 302 (Figure 3) decreases.

[0022] In another example, platelets of highly oriented pyrolysis graphite have an average platelet diameter ranging from 5 μm to 25 μm. This range is determined to be optimal for the maximum adhesion and conductivity of the conductor 304.

[0023] The propellant is any propellant suitable for propelling a solid powder composition. In one example, the propellant is an inert propellant. By selecting an inert propellant, chemical reactions between the solid powder composition and the propellant can be avoided.

[0024] In another example, the inert gas propellant has an atomic number greater than 17. By selecting a gas propellant with an atomic number greater than 17, the inert gas has a sufficiently high density to propel the solid powder composition. As an example, the inert gas propellant includes argon, which has an atomic number greater than 17 and is a highly clean inert gas, resulting in less oxidation or captured oxygen upon impact of the solid powder composition onto the substrate 302 compared to helium or nitrogen. The use of argon, or other gas propellants with an atomic number greater than 17, also maximizes the conductivity of highly oriented pyrolysis graphite by avoiding oxidation and reducing the possibility of corrosion occurring due to the introduction of dissimilar metals (e.g., copper particles into a metal substrate).

[0025] In another example, the conductor 304 (Figure 3) has an average thickness T of 100-200 μm. E It has an average thickness T. EIf the average thickness T is less than 100 μm, the conductivity of the conductor 304 (Figure 3) decreases. E If the thickness is greater than 200 μm, the weight of the conductor 304 (Figure 3) increases, and the effect of improving conductivity by including highly oriented pyrolysis graphite begins to decrease.

[0026] Figure 2 is a schematic diagram of an example of a system 200 that may be used to carry out the method 100 shown in Figure 1.

[0027] As shown in Figure 2, system 200 includes an optical sensor 216, a controller 218, a first regulator 204, a heater 206, a second regulator 210, and an actuator 214. System 200 may further include a third regulator 222, a fourth regulator 226, and a fifth regulator 230. Without departing from the scope of this disclosure, system 200 may include additional components such as additional regulators.

[0028] The optical sensor 216 communicates with the controller 218 via the communication line 250. The communication line 250, like all other communication lines 251, 252, 253, 254, 255, 260, and 262 in the system 200, may be wired or wireless. The optical sensor 216 is connected to the thickness T of the coating material 303 applied to the substrate 302. C Data indicating this can be transmitted to the controller 218. The measured thickness T of the coating material 303 applied to the substrate 302. C Based at least on operator input, the controller 218 generates command signals that control the amount of gas propellant to be heated, the temperature at which the gas propellant is heated, the amount of solid powder composition to be mixed with the heated gas in the nozzle 212, and the distance M between the nozzle 212 and the substrate 302.

[0029] The first regulator 204 communicates with the controller 218 via the communication line 251. The amount of gas propellant supplied to the heater 206 can be controlled by the control of the first regulator 204.

[0030] The heater 206 receives the gas propellant supplied by the first regulator 204 and heats the gas propellant to the required temperature according to the commands of the controller 218 via the communication line 260.

[0031] The second regulator 210 communicates with the controller 218 via the communication line 252. The amount of solid powder composition introduced into the gas propellant is controlled by the control of the second regulator 210.

[0032] The actuator 214 communicates with the controller 218 via the communication line 262. Command signals from the controller 218 received by the actuator 214 can move the nozzle 212 relative to the substrate 302. For example, the actuator 214 can move the nozzle 212 to achieve a desired distance M between the nozzle 212 and the substrate 302.

[0033] Therefore, the system 200 can control method 100 in real time to provide a certain result.

[0034] The system 200 may further include a tank 202 configured to store a gas propellant supplied by a first regulator 204. In one embodiment, the tank 202 supplies an inert gas propellant. In an exemplary embodiment, the tank 202 stores an inert gas propellant having an atomic number greater than 17 (e.g., argon).

[0035] The first regulator 204 includes any pressure or flow rate regulator that controls the output pressure or flow rate of the fluid to a desired value. For example, the first regulator 204 includes a valve. The output pressure or flow rate of the first regulator 204 can be adjusted based on command signals received from the controller 218 via the communication line 251.

[0036] The heater 206 includes any heater capable of heating a gas to a controlled temperature. The temperature of the heater 206 can be adjusted based on command signals received from the controller 218 via the communication line 260. In one example, the heater 206 is an electric heater. In another example, the heater 206 is a gas combustion heater.

[0037] System 200 may further include a feeder 208, which is defined as an optional device for storing a solid powder composition. In one example, the feeder 208 stores a mixture of the copper powder described above and platelets of highly oriented pyrolysis graphite. Thus, to carry out method 100, system 200 including a feeder 208 for storing a solid powder composition may be employed. However, alternatively, system 200 may include a feeder 208 for storing a liquid composition, so that system 200 may be employed to carry out a different method.

[0038] The second regulator 210 includes an optional pressure or flow rate regulator for controlling the output pressure or flow rate of a fluid or the flow amount of a solid powder composition to a desired value. In one example, the second regulator 210 includes a valve and a mass sensor. Using the mass sensor, the second regulator 210 can accurately measure the amount of solid powder composition passing through the second regulator 210. The amount of solid powder composition passing through the second regulator 210 can be adjusted based on a command signal received from the controller 218 via the communication line 252.

[0039] The system 200 further includes a nozzle 212. The nozzle 212 may include any device suitable for ejecting a solid powder composition supplied from the feeder 208 onto the substrate 302 using a heated gas propellant from the heater 206. In one example, the nozzle 212 includes a Laval nozzle used to accelerate a hot, pressurized gas passing through the Laval nozzle to supersonic speeds.

[0040] The actuator 214 may comprise any suitable driving device for moving the nozzle 212 along the substrate 302 at a predetermined distance M from the substrate 302. In one example, the actuator 214 may comprise a robotic actuator, such as a 6-axis robotic actuator arm. Moving the nozzle 212 using the actuator 214 facilitates maintaining control of the distance M between the nozzle 212 and the substrate 302. For example, the distance M between the nozzle 212 and the substrate 302 is typically in the range of 1 to 100 mm, preferably 5 to 20 mm.

[0041] The optical sensor 216 is configured to measure the thickness T of the coating material 303 applied on the substrate 302 C and comprises any optical sensor capable of monitoring and communicating with a controller 218 (via a communication line 250). The optical sensor 216, alone or in combination with the controller 218, performs real-time visual material thickness measurement on the surface of the substrate 302. Specifically, from the detection distance L0 between the sensor 216 and the substrate 302 obtained during an initial scan of the substrate 302, the detection distance L between the sensor 216 and the coating material 303 deposited on the substrate 302 during subsequent scans X is subtracted, whereby the thickness T of the coating material 303 deposited on the substrate 302 over time C can be measured. For example, during the initial scan, since no coating material 303 has been deposited on the substrate 302 yet, the initial distance L0 represents the distance between the sensor 216 and the substrate 302. In subsequent scans, the distance L X represents the distance between the sensor 216 and the exposed surface 305 of the coating material 303. It should be understood that as the thickness T of the coating material 303 C increases during the spraying process, the distance L between the sensor 216 and the exposed surface 305 of the coating material 303 X decreases proportionally.

[0042] An exemplary optical sensor 216 measures the distance L from the optical sensor to the exposed surface 305 of the coating material 303 XThere may be one or more optical distance sensors that use pulsed light signals to generate a signal (input to controller 218) representing the distance. The optical distance sensor operates by pulsed operation of a light-emitting diode (LED) to shine light on a target surface (first the surface of the substrate 302, then the exposed surface 305 of the coating material 303) and measuring the intensity of the reflected signal. Different reflectances of the target surface will result in different values ​​for the same distance. When the coating material 303 is applied to the substrate 302, the thickness T of the applied coating material... C As the distance L changes X It changes.

[0043] The controller 218 may be any device, system, or combination thereof (e.g., a microprocessor) capable of generating and transmitting command signals to obtain desired results from the controlled device. As shown by the dotted line in Figure 2, the controller 218 is communicatively coupled to the optical sensor 216, the first regulator 204, the second regulator 210, the heater 206, and the actuator 214.

[0044] In one example, the feeder 208 includes a first material feeder 220 for storing copper particles, a third regulator 222 for controlling the amount of copper particles from the first material feeder 220, a second material feeder 224 for storing plateslets of highly oriented pyrolysis graphite, a fourth regulator 226 for controlling the amount of highly oriented pyrolysis graphite plateslets from the second material feeder 224, and a mixer 228 that receives and mixes the copper particles supplied by the third regulator 222 and the highly oriented pyrolysis graphite plateslets supplied by the fourth regulator 226. Thus, the system 200 can adjust the relative amounts of copper particles and highly oriented pyrolysis graphite plateslets supplied from the feeder 208.

[0045] The first material feeder 220 includes any device suitable for supplying copper particles. In one example, the first material feeder 220 is a gravity powder feeder.

[0046] The third regulator 222 includes any regulator suitable for controlling the flow rate of copper particles to a desired value. In one example, the third regulator 222 includes a valve and a mass sensor. Using the mass sensor, the third regulator 222 can accurately measure the flow rate of copper particles passing through the third regulator 222.

[0047] The second material feeder 224 includes any device suitable for storing platelets of highly oriented pyrolysis graphite. In one example, the second material feeder 224 is a gravity powder feeder.

[0048] The fourth regulator 226 includes any regulator suitable for controlling the flow rate of platelets of highly oriented pyrolysis graphite to a desired value. In one example, the fourth regulator 226 includes a valve and a mass sensor. Using the mass sensor, the fourth regulator 226 can accurately measure the flow rate of platelets of highly oriented pyrolysis graphite passing through the fourth regulator 226.

[0049] The mixer 228 includes any device suitable for mixing copper particles passing from the third regulator 222 with highly oriented pyrolysis graphite platelets passing from the fourth regulator 226. In one example, the mixer 228 is a circular mixer.

[0050] In another example, a portion of the gas propellant supplied from tank 202 passes through a fifth regulator 230 (e.g., a valve) to transfer the solid powder composition supplied from feeder 208 to nozzle 212.

[0051] The thickness T of the coating material 303 was measured by the optical sensor 216. CBased on this, by using the controller 218 to control various functions of the system 200, the system 200 can control the process in real time to provide a consistent result when making a cold spray coated product 300 using method 100 as described in the following operating steps of the system 200.

[0052] The controller 218 operates the system 200 by using an optical sensor 216, for example, to measure the thickness T of the coating material 303 applied to the substrate 302. C This includes transmitting a signal indicating this to the controller 218 (via the communication line 250). Among the many possible factors, the measured thickness T C Based on the operator input, the controller 218 generates command signals that control the amount of propellant to be heated, the temperature at which the propellant is heated, the amount of solid powder composition to be mixed with the heated gas in the nozzle 212, and the distance M between the nozzle 212 and the exposed surface 305 of the coating material 303. The first regulator 204 receives the command signals and supplies the required amount of propellant. The heater 206 receives the propellant supplied from the first regulator and heats the propellant to the desired temperature. The second regulator 210 supplies the required amount of solid powder composition. The actuator 214 moves the nozzle 212 according to the commands of the controller 218 to facilitate the deposition of the coating material 303 on the substrate 302.

[0053] For example, the controller 218 may adopt one or more of the following relationships in order to provide the system 200 with more consistent results.

[0054]

number

[0055] V g -Gas velocity at nozzle outlet T-nozzle temperature of the gas before it reaches the nozzle R - Ideal gas constant = 8.31 J / mol P e -Gas pressure at nozzle outlet = 1 / 5(P i *V i ) / (V e ) Optimal conditions for metal matrix carbon-based composite materials V i - Volume at the gas inlet V e - Volume at nozzle outlet P i - Gas pressure supplied to the gun (optimal conditions for argon / composite particles are 1-3 MPa) M g - Molecular weight of gas γ-C p / C v (Isentropic expansion coefficient) C p - Heat capacity of gas at a constant pressure (for argon, Cp = 0.52) C v - Heat capacity of a gas in a given volume (for argon, Cv = 0.312)

[0056]

number

[0057] V p - Particle velocity at nozzle exit C D -The constant assumed to be equal to 1 in this equation ρ g - Gas density ρ p -Average density of particles D p - Average diameter of particles x - Distance M from nozzle to substrate ρ p =(%Wt m1 *ρ m1 )+[(1-(%Wt m1 ))*ρ m2 ] %Wt m1 - Weight percentage of material used ρ m1 -Average density of particles in material 1 ρm2 -Average density of particles in material 2 M fp =(ρ p *V e ) / t M fp - Particle mass flow rate at nozzle outlet t-time In summary, the System 200 described in this explanation can be summarized as follows:

[0058]

number

[0059] and

[0060]

number

[0061] The above formula can be utilized by the controller 218 using a lookup table of the gases and materials used, and the controller 218 can optimize the components of the system 200 in real time to satisfy the desired output parameters.

[0062] An exemplary specific method for operating system 200 to produce a cold-sprayed product is provided as follows: Tank 202 is filled with a predetermined amount of propellant gas (e.g., argon), and feeder 208 stores a mixture of copper particles having a current density of 500 amperes per square centimeter and platelets of highly oriented pyrolysis graphite intercalated with bromine.

[0063] The operator inputs various initial inputs to the controller 218. For example, the operator inputs the chemical composition of the substrate 302 and the desired thickness T of the conductor 304 (Figure 3) to be formed on the substrate 302. EAlong with (Figure 3), the chemical composition of the material in the first material feeder 220 (e.g., copper) and the chemical composition of the material in the second material feeder 224 (e.g., highly oriented pyrolysis graphite) are input to the controller 218.

[0064] When system 200 is activated, the optical sensor 216 begins monitoring the substrate 302 and the coating material 303 applied to the substrate 302. In real time, the optical sensor 216 monitors the thickness T of the coating material 303 (if any) on the substrate 302. C A signal indicating this is transmitted to the controller 218 (via the communication line 250).

[0065] Real-time measured thickness T of the coating material 303 on the substrate 302 C Based on the various initial inputs provided by the operator, the controller 218 determines the desired thickness T E Various command signals are generated to form a conductor 304 (Figure 3) having (Figure 3) on the substrate 302. The command signals are transmitted (via communication line 251) to the first controller 204, (via communication line 252) to the second controller 210, (via communication line 253) to the third controller 222, (via communication line 254) to the fourth controller 226, (via communication line 255) to the fifth controller 230, (via communication line 260) to the heater 206, and (via communication line 262) to the actuator 214.

[0066] Command signals transmitted by controller 218 (via communication line 251) to the first regulator 204 control the amount of gas propellant (supplied from tank 202) heated by heater 206. For example, a command signal received by the first regulator 204 may cause it to partially or completely open, thereby allowing propellant gas (e.g., argon) to flow into heater 206.

[0067] Command signals transmitted by controller 218 to the second regulator 210, third regulator 222, fourth regulator 226, and fifth regulator 230 (via communication lines 252, 253, 254, and 255, respectively) control the amount of solid powder composition mixed with the propellant gas and the chemical composition of the solid powder composition. For example, in feeder 208, based on the material ratio input to controller 218 by the operator, copper particles are supplied from the first material feeder 220 to the mixer 228, and platelets of highly oriented pyrolysis graphite are supplied from the second material feeder 224 to the mixer 228. As an example, the operator may want to make a conductor 304 (Figure 3) having 55-65 wt% copper and 35-45 wt% highly oriented pyrolysis graphite. In response to operator input, the controller 218 transmits a command signal (via communication line 253) to the third regulator 222 and a command signal (via communication line 254) to the fourth regulator 226. The command signals (transmitted via communication lines 253 and 254) function to operate the third regulator 222 and the fourth regulator 226, respectively, to ensure that desired amounts of both copper particles (in the first material feeder 220) and platelets of highly oriented pyrolysis graphite (in the second material feeder 224) are supplied to the mixer 228. When the second regulator 210 and the fifth regulator 230 are at least partially open, the Cu / HOPG metal matrix composite material is joined with a propellant gas (e.g., argon) and supplied to the nozzle 212.

[0068] A command signal (transmitted via communication line 252) operates the second regulator 210 to ensure that an appropriate amount of the mixture of copper particles and platelets of highly oriented pyrolytic graphite is mixed with a propellant gas (e.g., argon) passing through the fifth regulator 230 and transferred to the nozzle 212. At the nozzle 212, the transferred mixture of copper particles and platelets of highly oriented pyrolytic graphite is mixed with a heated propellant gas from the heater 206, thereby accelerating the mixture of copper particles and platelets of highly oriented pyrolytic graphite to a speed of 500-1,000 m / s. Thus, the mixture of copper particles and platelets of highly oriented pyrolytic graphite is propelled by the heated gas propellant and directed by the nozzle 212 toward the substrate 302 at a speed sufficient to plastically deform the solid powder composition and adhere it to the substrate 302 in order to deposit the conductor 304 onto the substrate 302.

[0069] Therefore, the transfer and composition of the material moving to the nozzle 212 can be controlled by the controller 218 by transmitting command signals to the first controller 204, the second controller 210, the third controller 222, the fourth controller 226, and the fifth controller 230.

[0070] Command signals transmitted by the controller 218 to the heater 206 (via the communication line 260) control the temperature at which the gas propellant is heated. For example, the controller 218 may instruct the heater 206 to heat to a temperature in the range of 450 to 535°C. Thus, the heater 206 heats the propellant gas (e.g., argon) to a temperature in the range of 450 to 535°C, and the heated propellant gas enters the nozzle 212.

[0071] Command signals transmitted by the controller 218 to the actuator 214 (via the communication line 262) control the distance M between the nozzle 212 and the substrate 302.

[0072] Therefore, the controller 218 controls the thickness T of the coating material 303 on the substrate 302.C Real-time data indicating the settings is received from the optical sensor 216, and among the many possible settings, the regulators 204, 210, 222, 226, 230, the heater 206, and the actuator 214 are controlled. As a result, the cold-spray coated product 300 shown in Figure 3 is formed, which includes a conductor 304 deposited on the substrate 302. The conductor 304 on the substrate 302 has a desired chemical composition and a desired thickness T E (Figure 3) is shown. For example, the conductor 304 includes a copper matrix 306 and highly oriented pyrolysis graphite platelets 308 dispersed in the copper matrix 306.

[0073] Figure 3 is a perspective view of an example of a cold-spray coated product 300 that is disclosed. The cold-spray coated product 300 includes a substrate 302 and a conductor 304 deposited on the substrate 302 by a method 100 using the system 200, etc.

[0074] The substrate 302 may include any metal substrate or any non-metal substrate. Preferably, the substrate 302 is selected from a material suitable for withstanding the heat and shock applied by the cold spray process. In one example, the substrate 302 is a metal substrate. In another example, the substrate 302 includes aluminum, titanium, or steel. In yet another example, the substrate 302 may be formed from aluminum alloy 7075 or aluminum alloy 7050.

[0075] The conductor 304 comprises a copper matrix 306 and highly oriented pyrolysis graphite platelets 308 dispersed in the copper matrix 306. Therefore, the conductor 304 provides a suitable alternative to conventional copper, having superior electrical performance and lower density than copper.

[0076] The copper matrix 306 includes pure copper, a copper-based alloy, or any alloy containing copper. By selecting the matrix as a copper matrix 306, the copper matrix 306 contributes to the high conductivity of the conductor 304.

[0077] For example, the current density of copper matrix 306 is approximately 500 amperes per square centimeter (500 A / cm²). 2 This makes it an ideal material for highly conductive matrix materials, particularly in applications such as aircraft maintenance, aircraft repair, and aircraft life monitoring.

[0078] In one example, the copper matrix 306 is included in the conductor 304 in an amount of 55-65% by weight. If the amount of copper matrix 306 is less than 55% by weight, the highly oriented pyrolysis graphite is not completely captured by the copper matrix 306 (Figure 3), and the adhesion of the conductor 304 to the substrate 302 (Figure 3) decreases. If the amount of copper matrix 306 is greater than 65% by weight, the overall conductivity of the conductor 304 (Figure 3) decreases, and the weight of the conductor 304 increases.

[0079] For example, the highly oriented pyrolysis graphite platelets 308 are included in the conductor 304 in an amount of 35-45% by weight. If the highly oriented pyrolysis graphite platelets 308 are included in the conductor 304 in an amount of less than 35% by weight, the overall conductivity of the conductor 304 (Figure 3) decreases, and the weight of the conductor 304 increases. If the highly oriented pyrolysis graphite platelets 308 are included in the conductor 304 in an amount greater than 45% by weight, the adhesion of the conductor 304 to the substrate 302 (Figure 3) decreases.

[0080] For example, the highly oriented pyrolysis graphite platelet 308 includes intercalated highly oriented pyrolysis graphite, such as bromine-intercalated highly oriented pyrolysis graphite. Due to the layered morphology of the graphite, different atomic or molecular species can be inserted between the graphite layers. The process of inserting such dopant species into graphite is called intercalation. Intercalation of highly oriented pyrolysis graphite is effective in altering the properties of the highly oriented pyrolysis graphite. Bromine-intercalated highly oriented pyrolysis graphite was deemed suitable for inclusion in the solid powder compositions of this disclosure.

[0081] In another example, the conductor 304 has an average thickness T of 100-200 μm. E It has an average thickness T. E If the average thickness T is less than 100 μm, the conductivity of the conductor 304 decreases. E If the thickness is greater than 200 μm, the weight of conductor 304 increases, and the effect of improving conductivity by including highly oriented pyrolysis graphite begins to decrease.

[0082] In one example, the conductor 304 is 7 × 10 7 ~S / cm 3 Exceeding 1 × 10, preferably 1 × 10 8 ~S / cm 3 More preferably 1.4 × 10 8 ~S / cm 3 It has an conductivity exceeding 1.0 to 8.0 g / cm³. In another example, conductor 304 has an conductivity of 1.0 to 8.0 g / cm³. 3 The range is preferably 2.0 to 6.0 g / cm³. 3 The range is, more preferably 3.0 to 4.0 g / cm³ 3 It has a density in the range of [value]. Therefore, conductor 304 can offer much higher conductivity and much lower density compared to pure copper.

[0083] An example of this disclosure may be described in relation to an aircraft manufacturing and maintenance method 1000, as shown in Figure 4, and an aircraft 1002, as shown in Figure 5. During prototyping, the aircraft manufacturing and maintenance method 1000 may include the specification and design 1004 and material procurement 1006 of the aircraft 1002. During production, the manufacturing of components / subassemblies 1008 and system integration 1010 of the aircraft 1002 are carried out. The aircraft 1002 may then undergo certification and transport 1012 to enter service 1014. During customer service, the aircraft 1002 is scheduled for periodic maintenance and inspection 1016, which may also include modifications, reconfigurations, and refurbishments.

[0084] Each process of Method 1000 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and subcontractors of key systems; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military, and maintenance company, etc.

[0085] The methods, systems, and products of this disclosure may be employed during any one or more stages of the aircraft manufacturing and maintenance methods 1000, including the specification and design of the aircraft 1002 1004, material procurement 1006, manufacturing of components / subassemblies 1008, system integration 1010, certification and transport 1012, aircraft commissioning 1014, and periodic maintenance and inspection 1016.

[0086] As shown in Figure 5, an aircraft 1002 produced by the exemplary method 1000 may include a fuselage 1018 together with a plurality of systems 1020 and internal 1022. An example of the plurality of systems 1020 may include one or more of the propulsion system 1024, electrical system 1026, hydraulic system 1028, and environmental system 1030. Any number of other systems may be included. The methods, systems, and products of this disclosure may be employed in any of the systems of the aircraft 1002.

[0087] Furthermore, this disclosure includes embodiments as defined below.

[0088] Clause 1. A method for creating a conductor 304 on a substrate 302 by cold spraying, wherein the method is A step of heating the gas propellant, A step of propelling a solid powder composition containing copper and highly oriented pyrolysis graphite using a heated gas propellant, The steps include: directing the solid powder composition toward the substrate 302 at a speed sufficient to plastically deform the solid powder composition and adhere it to the substrate 302 in order to deposit the conductive material 304 onto the substrate 302; Methods that include...

[0089] Clause 2. The current density of copper is approximately 500 amperes per square centimeter (500 A / cm²). 2 The method described in Article 1, which is as follows:

[0090] Clause 3. The method according to Clause 1, wherein the highly oriented pyrolysis graphite includes highly oriented pyrolysis graphite intercalated with bromine.

[0091] Clause 4. The method according to Clause 1, wherein the solid powder composition comprises copper particles and platelets of highly oriented pyrolysis graphite.

[0092] Clause 5. The method according to Clause 4, wherein copper particles are contained in the solid powder composition in an amount of 55-65% by weight.

[0093] Clause 6. The method according to Clause 4, wherein platelets of highly oriented pyrolysis graphite are contained in the solid powder composition in an amount of 35-45% by weight.

[0094] Clause 7. The method according to Clause 4, wherein the copper particles have an average particle size in the range of 15 μm to 25 μm.

[0095] Clause 8. The method according to Clause 4, wherein the platelets of highly oriented pyrolysis graphite have an average platelet diameter of 5 μm to 25 μm.

[0096] Clause 9. The method according to Clause 1, wherein the gas propellant is an inert gas propellant.

[0097] Clause 10. The method according to Clause 9, wherein the inert gas propellant has an atomic number greater than 17.

[0098] Clause 11. The method according to Clause 9, wherein the inert gas propellant comprises argon.

[0099] Clause 12. The method according to Clause 1, wherein the gas propellant is heated to a temperature in the range of 450 to 535°C.

[0100] Clause 13. Conductor 304 has an average thickness T of 100-200 μm. E The method described in Clause 1, having the following characteristics.

[0101] Clause 14. The method according to Clause 1, wherein the solid powder composition is directed toward the substrate 302 at a speed of 500 to 1,000 m / s.

[0102] Clause 15. A system 200 for spraying a coating material 303 onto a substrate 302, wherein the system Thickness T of the coating material 303 applied to the substrate 302 C An optical sensor 216 positioned to monitor, A controller 218 that communicates with an optical sensor 216, wherein the controller has a thickness T C A controller 218 generates, at least based on, a first command signal 251 corresponding to the amount of gas propellant heated, a second command signal 260 corresponding to the temperature at which the gas propellant is heated, a third command signal 252 corresponding to the amount of solid powder composition mixed with the heated gas in the nozzle 212, and a fourth command signal 262 corresponding to the distance M between the nozzle 212 and the substrate 302. A first regulator 204 receives a first command signal 251 and supplies an amount of gas propellant corresponding to the first command signal, A heater 206 receives an amount of gas propellant supplied from a first regulator, receives a second command signal 260, and heats the gas propellant to a temperature corresponding to the second command signal 260, A second regulator 210 receives a third command signal 252 and supplies an amount of solid powder composition corresponding to the third command signal 252 to the nozzle 212, Upon receiving the fourth command signal 262, actuator 214 moves the nozzle 212 along the substrate by a distance M between the nozzle 212 and the substrate 302, corresponding to the fourth command signal 262. System 200, which includes the above.

[0103] Clause 16. The system according to Clause 15, further comprising a tank 202 configured to store a gas propellant supplied by a first regulator 204.

[0104] Clause 17. The system described in Clause 16, wherein tank 202 supplies an inert gas propellant.

[0105] Clause 18. The system according to Clause 16, wherein tank 202 supplies an inert gas propellant having an atomic number greater than 17.

[0106] Clause 19. Tank 202 supplies argon to the system as described in Clause 16.

[0107] Clause 20. The system according to Clause 15, wherein the first regulator 204 comprises a valve.

[0108] Clause 21. The system according to Clause 15, wherein the second regulator 210 comprises a valve and a mass sensor.

[0109] Clause 22. The system according to Clause 15, further comprising a feeder 208 configured to store a solid powder composition supplied by a second regulator 210.

[0110] Clause 23. The system as described in Clause 22, wherein the feeder 208 stores a mixture of copper particles and platelets of highly oriented pyrolysis graphite.

[0111] Clause 24. Feeder 208, A first material feeder 220 for storing copper particles, A third regulator 222 supplies a certain amount of copper particles from the first material feeder 220, A second material feeder 224 for storing platelets of highly oriented pyrolysis graphite, A fourth regulator 226 supplies a certain amount of highly oriented pyrolysis graphite platelets from a second material feeder 224, A mixer 228 receives and mixes copper particles supplied by the third regulator 222 and plateslets of highly oriented pyrolysis graphite supplied by the fourth regulator 226. The system described in Clause 23, comprising:

[0112] Clause 25. The system according to Clause 24, wherein the third regulator 222 comprises a valve and a mass sensor.

[0113] Clause 26. The system according to Clause 24, wherein the fourth regulator 226 comprises a valve and a mass sensor.

[0114] Clause 27. The system according to Clause 15, wherein a portion of the gas propellant from tank 202 passes through a fifth regulator 230 and transfers a solid powder composition supplied from second regulator 210 to nozzle 212.

[0115] Clause 28. Cold spray coated product 300, Circuit board 302 and A conductor 304 deposited on a substrate 302 by cold spray, wherein the conductor 304 includes a copper matrix 306 and highly oriented pyrolysis graphite platelets 308 dispersed in the copper matrix 306, and Product 300, which includes the following features.

[0116] Clause 29. The product described in Clause 28, wherein the substrate 302 is a metal substrate.

[0117] Clause 30. The product described in Clause 28, wherein the substrate 302 comprises aluminum, titanium, or steel.

[0118] Clause 31. The product described in Clause 28, wherein the current density of the copper matrix 306 is approximately 500 amperes per square centimeter.

[0119] Clause 32. The product according to Clause 28, wherein the copper matrix 306 is contained in the conductor 304 in an amount of 55-65% by weight.

[0120] Clause 33. The product according to Clause 28, wherein the highly oriented pyrolysis graphite platelets 308 include platelets of highly oriented pyrolysis graphite intercalated with bromine.

[0121] Clause 34. The product described in Clause 28, wherein highly oriented pyrolysis graphite platelets 308 are included in the conductor 304 in an amount of 35-45% by weight.

[0122] Clause 35. The conductor 304 has an average thickness T of 100-200 μm. E The method described in Article 28, which has the following characteristics.

[0123] Clause 36. Conductor 304 is 3.0 to 4.0 g / cm³ 3 The product described in Clause 28, having a density within the range of [specified range].

[0124] Clause 37. Conductor 304 is 1.4 × 10 8 ~S / cm 3 The product described in Clause 28, having conductivity exceeding [a certain value].

[0125] While various examples of the disclosed methods, systems, and products have been shown and described, those skilled in the art will be able to conceive of modifications by reading this specification. This application includes such modifications and is limited only by the claims. [Explanation of Symbols]

[0126] 200 Systems 202 Tank 204 First regulator 206 Heater 208 Feeder 210 Second regulator 212 nozzles 214 Actuator 216 Optical Sensors 218 Controllers 220 First material feeder 222 Third regulator 224 Second material feeder 226 The fourth regulator 228 Mixer 230 Fifth regulator 250 communication lines 251 Communication line, first command signal 252 Communication line, third command signal 253 Communication Line 254 communication lines 255 communication lines 260 communication line, second command signal 262 Communication line, fourth command signal 300 cold spray coated products 302 circuit board 303 Coating materials 304 Conductors, materials 305 Exposed surface 306 Copper Matrix 308 Highly Oriented Pyrolysis Graphite Platelets 1000 Maintenance and Inspection Methods 1002 Aircraft 1004 Specifications and Design 1006 Material Procurement 1008 Manufacturing of components / partial assemblies 1010 System Integration 1012 Authentication and Transport 1014 Aircraft in service 1016 Periodic maintenance and inspection 1018 aircraft 1020 Multiple Systems 1022 Internal 1024 Propulsion System 1026 Electrical Systems 1028 Hydraulic System 1030 Environmental Systems Detection distance between L0 sensor and substrate L X Detection distance between the coating material deposited on the substrate and the sensor M is the distance between the nozzle and the substrate. T C Thickness of the coating material applied to the substrate T E Average thickness

Claims

1. A method (100) for creating a conductor 304 on a substrate 302 by cold spray, wherein the method (100) is A step of heating the gas propellant (102), Step (104) of propelling a solid powder composition containing copper and highly oriented pyrolysis graphite using the heated gas propellant, Step (106) of directing the solid powder composition toward the substrate 302 at a speed sufficient to plastically deform the solid powder composition and adhere it to the substrate 302 in order to deposit the conductor 304 onto the substrate 302. Method (100), including the method (100).

2. The step of propelling the solid powder composition involves a current of 500 amperes per square centimeter (500 A / cm²). ２ The method according to claim 1 (100), further comprising the step of propelling a solid powder composition containing copper having a current density of ).

3. The method according to claim 1 or 2 (100), wherein the step of propelling the solid powder composition further comprises the step of propelling the solid powder composition comprising highly oriented pyrolysis graphite comprising bromine intercalated highly oriented pyrolysis graphite.

4. The method according to any one of claims 1 to 3 (100), wherein the step of propelling the solid powder composition further comprises the step of propelling the solid powder composition comprising copper particles and platelets of highly oriented pyrolysis graphite.

5. The method according to any one of claims 1 to 4 (100), wherein the step of propelling the solid powder composition further comprises propelling the solid powder composition comprising 55 to 65% by weight of copper particles and 35 to 45% by weight of platelets of highly oriented pyrolysis graphite.

6. The method according to any one of claims 1 to 5 (100), wherein the step of propelling the solid powder composition further comprises the step of propelling the solid powder composition comprising copper particles having an average particle size in the range of 15 μm to 25 μm.

7. The method according to any one of claims 1 to 6 (100), wherein the step of propelling the solid powder composition further comprises the step of propelling the solid powder composition comprising platelets of highly oriented pyrolysis graphite having an average platelet diameter of 5 μm to 25 μm.

8. A system 200 for spraying a coating material 303 onto a substrate 302, wherein the system is The thickness T of the coating material 303 applied to the substrate 302 Ｃ An optical sensor 216 positioned to monitor, A controller 218 that communicates with the optical sensor 216, wherein the controller has the thickness T Ｃ A controller 218 generates, at least based on, a first command signal 251 corresponding to the amount of gas propellant to be heated, a second command signal 260 corresponding to the temperature at which the gas propellant is heated, a third command signal 252 corresponding to the amount of solid powder composition mixed with the heated gas in the nozzle 212, and a fourth command signal 262 corresponding to the distance M between the nozzle 212 and the substrate 302, A first regulator 204 receives the first command signal 251 and supplies an amount of gas propellant corresponding to the first command signal, A heater 206 receives the amount of gas propellant supplied from the first regulator, receives the second command signal 260, and heats the gas propellant to the temperature corresponding to the second command signal 260, A second regulator 210 receives the third command signal 252 and supplies an amount of solid powder composition corresponding to the third command signal 252 to the nozzle 212, An actuator 214 receives the fourth command signal 262 and moves the nozzle 212 along the substrate by a distance M between the nozzle 212 and the substrate 302 that corresponds to the fourth command signal 262. System 200, which includes the following.

9. The system further comprises a feeder 208 for storing the solid powder composition supplied by the second regulator 210, and the feeder 208 is A first material feeder 220 for storing copper particles, A third regulator 222 supplies a certain amount of copper particles from the first material feeder 220, A second material feeder 224 for storing platelets of highly oriented pyrolysis graphite, A fourth regulator 226 supplies a certain amount of highly oriented pyrolysis graphite platelets from the second material feeder 224, A mixer 228 receives and mixes the copper particles supplied by the third regulator 222 and the platelets of highly oriented pyrolysis graphite supplied by the fourth regulator 226. The system 200 according to claim 8, comprising:

10. A cold spray coated product 300 made using the method (100) according to any one of claims 1 to 7 or the system 200 according to claim 8 or 9, wherein the cold spray coated product is Circuit board 302 and A conductor 304 deposited on the substrate 302 by cold spray, wherein the conductor 304 includes a copper matrix 306 and platelets 308 of bromine-intercalated highly oriented pyrolysis graphite dispersed in the copper matrix 306. A cold-spray coated product 300, equipped with [the specified feature].

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