Cold-Spray Nozzle Cooling via Refrigerant Phase Transition
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Solution Overview
Problem
The cold-spray deposition process is hindered by nozzle clogging, which limits the duration and types of particles that can be used, leading to increased costs and inefficiency due to the need for frequent nozzle cleaning or replacement, despite previous attempts with water-cooled jackets being insufficient.
Innovation Solution
A method involving a compressed cooling fluid that expands or vaporizes near the nozzle to cool it, integrated into a spray head with a coaxially oriented cooling jacket, which extends the nozzle's operational time and reduces clogging by maintaining lower temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water-cooled jackets are used to cool the nozzle, then nozzle temperature is reduced, but clogging is not prevented and spray time is not extended
Solution Approach 1:
The patent employs phase transition of a refrigerant fluid within the cooling jacket to achieve superior cooling效果. The refrigerant circulates through phase changes (liquid to vapor and back), absorbing and releasing heat efficiently, which maintains the nozzle at temperatures that prevent particle clogging during cold-spray deposition
Solution Approach 2:
The patent uses a closed-loop hydraulic cooling system with a refrigerant fluid circulating through the cooling jacket. The system utilizes pump-driven fluid circulation and pressure-controlled phase transitions to achieve reliable temperature control, preventing clogging effectively
2Reliability
If deposition is halted for nozzle cleaning or replacement, then clogging is addressed, but productivity is reduced and costs increase
Solution Approach 1:
The patent implements preliminary cooling action by maintaining the nozzle at optimal temperature throughout the deposition process. The cooling system is activated before clogging can occur and continues operationally, preventing particle adhesion and extending deposition time without interruption
Solution Approach 2:
The patent achieves continuous deposition operation by maintaining constant nozzle cooling throughout the process. The closed-loop refrigerant system operates continuously, ensuring the nozzle remains at the correct temperature to prevent clogging and allow uninterrupted particle deposition
3Speed
If high temperatures and pressures are used for cold-spray deposition, then particle acceleration is improved, but nozzle clogging occurs more frequently
Solution Approach 1:
The patent applies local quality by creating a temperature gradient through the cooling jacket design. The refrigerant system provides targeted cooling at the nozzle wall where particles contact, allowing high internal temperatures for particle acceleration while maintaining cool external surfaces that prevent clogging
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 solution significantly extends the duration of cold-spray deposition by 2.5 to 20 minutes, allowing for longer use without clogging, even at high temperatures and pressures, and enables the use of less expensive gases like nitrogen, thereby reducing costs and increasing nozzle lifespan.
Implementation Method 1
cooling the nozzle by at least one of expanding and vaporizing a compressed cooling fluid in proximity to the nozzle
Implementation Method 2
cooling the nozzle by at least one of expanding and vaporizing a compressed cooling fluid in proximity to the nozzle
Implementation Method 3
compressed cooling fluid which expands, vaporizes, or both, in proximity to the nozzle to effect cooling
Data Source
AI summary
Various embodiments disclosed relate to a method of cold-spray deposition involving cooling the cold-spray nozzle by at least one of expanding and vaporizing a compressed cooling fluid in proximity to the cold-spray nozzle. The present disclosure also includes a cold-spray deposition spray head, a cooling jacket for a cold-spray deposition nozzle and a cold-spray deposition system comprising the same.