Cold Spray Leak Repair for Pressurized Pipes and Vessels
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Solution Overview
Problem
Current cold spray technologies are unable to repair active leaks in operational equipment and systems, such as aircraft hydraulic lines and piping, as they require shutdown and disassembly, leading to downtime and inefficiency.
Innovation Solution
A method and system for cold spraying that allows for the repair of active leaks by identifying and sealing leaks in situ using a pressurized gas and metal powder mixture, administered through a spray gun, while the system is still operational, using a cold spray system comprising a dry powder source, gas source, mixing manifold, and accelerant, which forms a strong mechanical and metallurgical bond without shutting down the equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cold spray systems are used to repair leaks, then a strong metallurgical bond is achieved, but the equipment must be shut down and disassembled, causing downtime
Solution Approach 1:
A wedge or plug is inserted into the leak hole before initiating the cold spray process. This preliminary action contains the pressurized fluid, allowing the cold spray to be applied effectively to seal the leak without requiring system shutdown or disassembly, thereby eliminating downtime while maintaining strong bond strength
Solution Approach 2:
The wedge or plug serves as an intermediary element inserted into the leak hole to contain pressurized fluid. This mediator enables the cold spray process to work effectively on pressurized systems by creating a controlled environment for material deposition, resolving the contradiction between maintaining system operation and achieving proper bond strength
2Reliability
If wrapping or sleeving is applied to prevent chaffing, then chaff prevention is achieved, but the wrap and sleeve wear down over time and do not maintain good surface bond
Solution Approach 1:
The mechanical wrapping or sleeving system is replaced with a cold spray coating system. The cold spray process deposits metallic or ceramic particles that form a strong, bonded protective layer on the hydraulic line surface, providing chaff prevention with superior durability and surface adhesion compared to mechanical wraps or sleeves
Solution Approach 2:
The cold spray process applies composite coating materials (metallic or ceramic particles) onto the hydraulic line surface. These composite materials provide enhanced wear resistance and chaff prevention capabilities while maintaining strong surface bonding, overcoming the limitations of single-material wraps or sleeves
3Ease of repair
If the hydraulic line is removed from operation for repair, then effective repair can be performed, but aircraft downtime increases
Solution Approach 1:
The cold spray repair system enables the hydraulic line to be repaired in situ while remaining in operation. The system uses the line's own pressurized fluid to contain the leak (with the wedge/plug) and delivers coating material directly to the damaged area, allowing the aircraft to remain in service throughout the repair process and maintaining high utilization
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 repair of active leaks in operational systems, reducing downtime and maintaining system functionality, with the ability to restore components to their original dimensions and performance, achieving a strong bond that meets OEM standards.
Implementation Method 1
specially engineered sub-micron and micron sized solid state particles are accelerated to supersonic speeds through a convergent-divergent nozzle using such gases as helium and nitrogen
Implementation Method 2
When the particles impact the surface, they form a strong mechanical and metallurgical bond
Implementation Method 3
administering pressurized gas and metal powder to an active pipe leak... depositing cold spray material onto the piping structure at the hole
Data Source
AI summary
A method of repairing an active leak in embodiments of the present invention may include one or more of the following steps: (a) identifying the active leak on a pipe structure, tank or pressure vessel, (b) setting cold spray system settings to repair the pipe structure, (c) administering pressurized gas and metal powder to an active pipe leak, (d) identifying any potential hazards surrounding the active pipe leak, (e) eliminating and/or reducing the potential hazards surround the active pipe leak, (f) inserting a wedge within an active leak pipe hole, (g) ceasing administration of pressurized gas and metal powder to the active pipe leak when it appears sealed, (h) verifying the active pipe leak is sealed, and (i) re-administering the pressurized gas and the metal powder to the active leak is the active leak is not fully sealed.