In-situ Cold Spray Adhesion Testing Apparatus
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Solution Overview
Problem
Existing methods for verifying the bond strength of cold spray deposits on surfaces with oxide deposits or debris, especially in confined spaces, are not suitable for field conditions due to limitations in standoff distances and nozzle sizes, necessitating a method to assess the quality of cold spray deposits in situ.
Innovation Solution
A testing arrangement comprising a specimen member with apertures and a loading arrangement that applies a known mechanical force to determine the shear stress required to dislodge the cold spray deposit from the surface, allowing for in-situ adhesion testing by measuring the force needed to unbond the deposit from the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional adhesion testing methods are used, then bond strength can be measured, but the testing cannot be performed in situ under field conditions
Solution Approach 1:
The testing arrangement is divided into separate functional components: a specimen member with apertures for deposit formation, a loading arrangement for applying force, and a measurement system. This segmentation allows the testing device to be configured for in-situ field conditions while maintaining measurement capability.
Solution Approach 2:
The invention transitions from conventional laboratory-based testing to in-situ field testing by creating a new dimensional approach where the specimen member with apertures is positioned directly on the substrate surface during field operations, enabling bond strength verification in previously inaccessible environments.
2Ease of manufacture
If cold spray deposition is performed on surfaces with oxide deposits or debris, then repair can be conducted on in-service structures, but the bond strength of the deposit is detrimentally affected
Solution Approach 1:
The specimen member with apertures is positioned and prepared before cold spray deposition, creating a controlled test area that allows subsequent measurement of actual bond strength. This preliminary setup enables the assessment of deposition quality despite varying surface conditions.
Solution Approach 2:
The invention replaces conventional destructive mechanical testing methods with an in-situ shear force measurement system that applies controlled mechanical loading through the loading arrangement to directly measure bond strength at the deposition interface under field conditions.
3Ease of operation
If limited standoff distances are used during cold spray deposition, then access to confined spaces is enabled, but suboptimal nozzle sizes and positioning result in reduced deposit quality
Solution Approach 1:
The specimen member with apertures serves a dual function: it acts as a template for uniform deposit formation and as a specimen for subsequent bond strength testing. This self-service approach allows quality verification without requiring separate test coupons or additional positioning equipment.
Solution Approach 2:
The testing arrangement integrates multiple functions into a single device: the specimen member facilitates both deposit formation and bond strength measurement, while the loading arrangement provides both mechanical support and force application. This multi-functionality enables comprehensive quality assessment in confined spaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the assessment of cold spray deposit quality by determining the shear stress at the interface, ensuring the quality of repairs in field applications and mitigating the effects of surface debris and oxide deposits on bond strength.
Implementation Method 1
The shear stress inherently accounts for the metallurgical quality of the deposit at the substrate/deposit interface
Implementation Method 2
a load cell that determines the mechanical force provided by the mechanical actuator
Data Source
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AI summary
A testing arrangement and method of using in performing an in-situ adhesion test of a cold spray deposit on a surface of a structure. The testing arrangement includes a specimen member having a number of apertures defined therein and a loading arrangement coupled to the specimen member. The loading arrangement is configured to provide a mechanical force of a known magnitude to the specimen member. In performing an in-situ test of a cold spray deposit on a structure, the method includes positioning the testing arrangement with respect to a surface of the structure, depositing the cold spray deposit on the surface of the structure, and testing the adhesion of the cold spray deposit to the surface.