Cold Spray Aluminum Coating for Adhesion and Heat Dissipation
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Solution Overview
Problem
Existing methods for forming metallic coatings on substrates using the cold spray method do not adequately achieve high adhesive strength and efficient heat dissipation simultaneously.
Innovation Solution
A method involving the use of a powdered material with aluminum or aluminum alloy as the main component, including a brazing filler metal or magnesium as an additive, is applied to the substrate using a cold spray device, followed by heat treatment to form a metallic coating with irregular asperities, enhancing adhesive strength and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cold spray method is used to form a metallic coating on a substrate, then thermal stress is reduced and oxidation is controlled, but the adhesive strength and heat dissipation efficiency are insufficient
Solution Approach 1:
The patent applies preliminary action by performing surface roughening treatment on the substrate before forming the metallic coating. This creates irregular asperities on the substrate surface in advance, which will later provide anchor points for the coating material, thereby improving adhesive strength without requiring high-energy thermal spray processes.
Solution Approach 2:
The patent changes the surface topology parameter of the substrate by creating irregular asperities through surface roughening treatment. This parameter change increases the effective surface area and provides mechanical interlocking features, enabling both high adhesive strength and efficient heat dissipation while maintaining the low-temperature advantage of cold spray method.
2Loss of energy
If the surface is made rough to enable efficient heat dissipation, then heat dissipation efficiency is improved, but the adhesive strength may be compromised
Solution Approach 1:
The surface roughening treatment is performed as a preliminary action before coating formation. This creates the desired irregular asperities on the substrate surface in advance, which serve dual purposes: enhancing heat dissipation efficiency through increased surface area and providing mechanical anchor points for the subsequent metallic coating, thereby maintaining adhesive strength.
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
The method achieves high adhesive strength and efficient heat dissipation by forming a metallic coating with controlled oxidation and reduced thermal stress, utilizing the anchor effect and heat treatment to improve bond strength and surface roughness.
Implementation Method 1
a preprocessing step of forming a preprocessing coating on the surface of the substrate by accelerating the powdered material together with gas and spraying the powdered material in a solid phase onto the surface of the substrate
Implementation Method 2
a coating forming step of forming a heat-treated coating having a surface with irregular asperities by heating a preprocessing laminate in which the preprocessing coating is formed on the surface of the substrate
Implementation Method 3
impact of a powdered metal material on the substrate (or a preliminarily formed coating) generates plastic deformation between the powder and the substrate, yielding anchor effect
Implementation Method 4
a metallic coating may have a function of dissipating heat of a substrate to the outside... a surface where heat dissipation is performed is made rough to enable efficient heat dissipation
Data Source
AI summary
A method of manufacturing a laminate includes: forming a preprocessing coating on a surface of a substrate having insulating properties by accelerating the powdered material together with gas and spraying the powdered material in a solid phase onto the surface of the substrate, the powdered material including aluminum or an aluminum alloy as a main component; and forming a heat-treated coating having a surface with irregular asperities by heating a preprocessing laminate including the substrate and the preprocessing coating formed on the surface of the substrate.