Cold Spray MAXMET Composite Coating Process
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Solution Overview
Problem
MAXMET materials face limitations in thermodynamic stability and manufacturing costs when processed at high temperatures for high-temperature applications, particularly in thermal spraying routes, which can lead to decomposition and oxidation of MAX phase reinforcement.
Innovation Solution
A cold spraying process is employed to form MAXMET composite coatings on substrates using a mixture of MAX phase particles and metal, with a metallic shell to minimize oxidation and decomposition, and a carrier gas like nitrogen or helium, at a critical velocity that ensures effective deposition without melting, allowing for lower temperature processing and efficient deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal spraying routes are used to manufacture MAXMET coatings, then high temperature processing is achieved, but MAX phase reinforcement loses thermodynamic stability and decomposes
Solution Approach 1:
The invention changes the temperature parameter from high (thermal spraying) to low (cold spraying below melting point), thereby preserving the thermodynamic stability of the MAX phase while still achieving effective coating deposition through kinetic energy of particles
Solution Approach 2:
The invention replaces thermal energy (heat) with mechanical energy (kinetic energy of accelerated particles) as the primary mechanism for particle deposition, eliminating the need for high temperatures that cause MAX phase decomposition
2Manufacturing precision
If spray drying of MAX phase powder with metal powder is performed prior to thermal spraying, then MAXMET composite coatings are formed, but manufacturing cost increases and yield decreases
Solution Approach 1:
The invention extracts and eliminates the unnecessary spray drying step from the manufacturing process, directly cold spraying the MAX phase and metal powder mixture without intermediate processing, thereby simplifying the workflow and improving yield
Solution Approach 2:
The invention performs preliminary mixing of MAX phase and metal powders in appropriate ratios before cold spraying, ensuring proper composite formation without requiring post-mixing spray drying steps, thus improving manufacturing efficiency
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 cold spraying method retains the thermodynamic stability of MAX phase reinforcement, reduces manufacturing costs, and enhances the mechanical properties and erosion resistance of MAXMET composites, achieving dense and low-porosity coatings with improved yield and reduced oxidation.
Implementation Method 1
Cold spraying the at least one powder on the substrate at a critical velocity. Forming a layer of the MAXMET composite on the substrate
Implementation Method 2
cold spraying process is employed to form MAXMET composite coatings on substrates using a mixture of MAX phase particles and metal... at a critical velocity that ensures effective deposition without melting
Implementation Method 3
with a metallic shell to minimize oxidation and decomposition
Implementation Method 4
supplying the MAXMET composite powder to a spray gun using a helium primary gas flow of from about 5 m3/h to about 250 m3/h, said powder carrier gas flow rate exiting the spray gun of 2 m3/h to 12 m3/h
Data Source
AI summary
A process of forming a MAXMET composite coating or component on an article, that in the case of components can be removed, comprising providing an article having a substrate. The process includes providing at least one powder containing the MAXMET composite, wherein the MAXMET composite comprises a mixture of MAX phase particles and metal. Cold spraying the at least one powder on the substrate at a critical velocity. Forming a layer of the MAXMET composite on the substrate.