Cold Spray Structure Paths That Avoid Intersection Buildup
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Solution Overview
Problem
In cold gas spraying, intersections of the travel path outside the functional geometry lead to undesirable excess elevations and collisions with molding tools, making it difficult to manufacture complex structures without material accumulation at these points.
Innovation Solution
The method involves using an element with a surface that has lower coatability or acts as an absorber, allowing the cold gas particles to penetrate or not adhere, thereby reducing material application at intersections and enabling the production of complex structures by arranging these intersections on the element surface or optimizing the travel path to avoid excessive material deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the travel path is extended to cover complex structures, then manufacturing capability is improved, but material accumulation at intersections occurs
Solution Approach 1:
A sacrificial element is introduced as an intermediary component in the travel path. This element has a sacrificial surface that absorbs excess material deposition, preventing material accumulation on the final structure. The element acts as a mediator that intercepts the cold gas particle jet at intersection points, allowing the travel path to extend to complex structures without compromising manufacturing precision.
2Manufacturing precision
If constant travel speed is maintained for geometric mapping, then coating quality is improved, but intersections cannot be accommodated in complex structures
Solution Approach 1:
The sacrificial element serves as a mediator that enables the travel path to pass through intersection regions while maintaining constant travel speed. The element's sacrificial surface absorbs the excess material that would otherwise accumulate, allowing complex structures to be manufactured without compromising coating quality.
Solution Approach 2:
The sacrificial element creates a temporary copy or placeholder for the intersection region. By depositing material on the sacrificial surface instead of the final structure, the system replicates the material deposition process without creating defects in the target geometry.
3Area of stationary object
If material is deposited at intersections, then complete coverage is achieved, but excess elevations and collisions with molding tools occur
Solution Approach 1:
The sacrificial element acts as an intermediary that intercepts the cold gas particle jet at intersection points. It absorbs the material deposition that would otherwise create excess elevations on the final structure, preventing collisions with molding tools while maintaining complete coverage of the target area.
Solution Approach 2:
The sacrificial element is designed to be disposable or easily removable. It accepts material deposition temporarily, serving its purpose during the spraying process, and can then be removed or discarded without affecting the final structure. This disposable approach eliminates the need to avoid intersections entirely.
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
This approach allows for efficient production of complex structures by minimizing material application at critical regions, protecting sensitive areas, and enabling the creation of structures with reduced material usage and smaller structural space, such as winding heads for electric machines.
Implementation Method 1
the element surface (70) is embodied as an absorber for particles of the cold gas spraying method
Implementation Method 2
the element surface (70) is embodied such that particles of the cold gas spraying method penetrate into the element surface (70)
Data Source
AI summary
Various embodiments include a method for producing a structure with a cold gas spraying method comprising: providing a carrier with a carrier surface, to which the structure is to be attached by the cold gas spraying method by following a travel path; and providing an element with an element surface different from the carrier surface. The element is arranged in the travel path and/or the travel path is specified such that intersections of the travel path and/or interruptions of the structure are arranged on the element surface.