Cold Spray Wrought Forming with Lateral Compression Heating
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Solution Overview
Problem
Existing methods for producing wrought structures from cold spray deposition, such as HIPing, are energy intensive, costly, and time-consuming, and can result in structural issues like thermal stresses and oxidation, while also being limited by the need for specialized equipment and restricted to certain geometries.
Innovation Solution
A process involving simultaneous application of heat and lateral compressive load to a cold spray deposited preform, raising the temperature between the recrystallisation temperature and melting point to transform the material into a wrought structure without melting, using techniques like rapid heating and pulsed current, allowing for continuous processing and reduced porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If HIPing process is used to produce wrought structures from cold spray deposition, then porosity is reduced and material density is improved, but energy consumption increases and processing time is extended
Solution Approach 1:
The invention changes the processing parameters by applying lateral compressive load combined with controlled heating to reach recrystallization temperature, replacing the conventional HIPing parameters of high isostatic pressure and extended holding time. This parameter change achieves porosity reduction while significantly reducing energy consumption and processing time
Solution Approach 2:
The invention substitutes the complex isostatic pressing mechanical system with a simpler lateral compression system combined with thermal treatment. Instead of using multi-directional high pressure equipment, the patent uses uniaxial or biaxial lateral compression with heating, replacing the cumbersome HIPing mechanical apparatus with a more efficient system
2Manufacturing precision
If HIPing process is used to produce wrought structures, then material density is improved, but processing cost increases and equipment complexity increases
Solution Approach 1:
The invention extracts the essential function of porosity reduction from the complex HIPing process, isolating the critical combination of compression and heating. By removing the isostatic pressing component and retaining only the effective lateral compression and thermal treatment elements, the patent simplifies the equipment while maintaining material density improvement
Solution Approach 2:
The lateral compression apparatus combined with heating can process various cold spray deposited geometries including complex shapes that HIPing cannot accommodate. The simplified equipment achieves multi-functionality by being able to process different geometries without requiring specialized containment chambers and isostatic pressure systems
3Manufacturing precision
If conventional cold spray methods are used to produce low porosity deposits, then porosity is reduced, but thermal stresses cause cracking and deposit separation occurs
Solution Approach 1:
The invention applies preliminary lateral compressive load before and during the heating process to prevent thermal stress accumulation. By pre-compressing the deposit and maintaining compression during recrystallization, the patent prevents cracking and separation that would otherwise occur during conventional heating processes
Solution Approach 2:
The invention merges the porosity reduction function with the structural integrity preservation function by simultaneously applying lateral compression and heating. This combined action achieves densification while the compressive load counteracts thermal stresses, preventing cracking and maintaining deposit-substrate bonding throughout the process
4Strength
If lateral compressive load and heat are applied simultaneously to cold spray preform, then wrought structure is formed with improved mechanical properties, but process complexity increases
Solution Approach 1:
The invention implements continuous lateral compression throughout the heating and recrystallization process, maintaining useful action continuously. The compressive load is applied from the beginning and maintained throughout temperature rise and holding, ensuring continuous porosity reduction and structural improvement without interruption or additional process steps
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 method enables the production of dense, high-strength wrought structures with improved ductility and mechanical properties, avoiding oxidation and melting-related defects, and is applicable to a wide range of metals, including titanium, with a lower carbon footprint and cost compared to traditional methods.
Implementation Method 1
the heating requirements of the accelerating gas required to achieve high velocities
Implementation Method 2
The kinetic energy of the particles is utilised to achieve bonding through plastic deformation upon impact with the substrate
Implementation Method 3
applying heat and a compressive load simultaneously to an application area of a cold spray deposition preform to transform the consolidated particle structure into a wrought structure
Implementation Method 4
a compressive load applicator configured to simultaneously apply heat and a compressive load to an application area of a cold spray deposition preform
Data Source
AI summary
A process and apparatus of producing a product having a wrought structure. The process comprises the step of: applying heat and a compressive load simultaneously to an application area of a cold spray deposition preform to transform the comprising consolidated particle structure into a wrought structure, the compressive load being applied laterally to the application area. The application of compressive load and heat to the application area raises the temperature of the material of the preform in the application area to between the recrystallisation temperature and the melting point of the material.