Cold-Sprayed Metal Casing Structure Without Thermal Distortion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional warhead casing manufacturing methods, such as casting and forging, are limited by tooling requirements, high energy consumption, and restricted design flexibility, leading to increased costs and reduced efficiency in developing new designs, while additive manufacturing methods like directed energy deposition suffer from thermal distortions.
Innovation Solution
The use of cold-gas dynamic spraying to additively manufacture bomb casings, specifically the conical nose and cylindrical body portions, with metal particles that maintain their properties without melting, allowing for integrated construction and customizable material composition through geometric features and interlaced layers for enhanced strength and penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional casting or forging methods are used to manufacture bomb casings, then the structural strength and hardness can be achieved, but the design flexibility is restricted and tooling requirements increase costs and development time
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from subtractive (molding/forging with fixed tooling) to additive (cold spray deposition), enabling design flexibility without traditional tooling constraints. This allows rapid prototyping and customization of casing geometries for different warhead applications.
Solution Approach 2:
The patent replaces the mechanical molding and forging systems with a cold spray additive manufacturing system. This substitution eliminates the need for complex molds and dies while achieving comparable or superior mechanical properties through controlled particle deposition and interlaced layer formation.
2Strength
If conventional casting or forging methods are used to manufacture bomb casings, then the structural strength can be achieved, but the energy consumption is significant
Solution Approach 1:
The patent converts the typically harmful effect of heat (which causes thermal distortion in conventional additive manufacturing) into a benefit by using cold spray technology. The kinetic energy of particles is converted into deposition energy without melting, avoiding thermal distortion while maintaining structural strength. This eliminates the need for post-manufacturing heat treatment in many cases.
Solution Approach 2:
The patent changes the energy input parameter from thermal (melting in conventional additive manufacturing) to kinetic (cold spray deposition). This parameter change reduces overall energy consumption while achieving equivalent or superior mechanical properties through cold-forming and work hardening effects during deposition.
3Adaptability or versatility
If directed energy deposition additive manufacturing is used to manufacture bomb casings, then design freedom is improved, but thermal distortion occurs due to concentrated heat application
Solution Approach 1:
The patent converts the harmful thermal distortion effect into a benefit by using cold spray technology where kinetic energy replaces thermal energy. The concentrated energy input that causes thermal distortion in laser-based systems is replaced by controlled kinetic energy deposition, eliminating thermal distortion while maintaining design freedom.
Solution Approach 2:
The patent changes the fundamental deposition parameter from thermal (melting and solidification in directed energy deposition) to kinetic (cold-forming and adhesion in cold spray). This parameter change eliminates thermal distortion while preserving the ability to create complex geometries and customized designs.
4Ease of manufacture
If conventional multi-part subassembly constructions are used for bomb casings, then the manufacturing process is established, but the parts count increases labour and production costs
Solution Approach 1:
The patent merges multiple separate components (nose cone, cylindrical body, tail portion) into a single monolithic structure manufactured by cold spray additive manufacturing. This consolidation eliminates assembly operations, reduces parts count, and lowers labor costs while maintaining or improving structural integrity through continuous material deposition.
Solution Approach 2:
The cold spray additive manufacturing system serves multiple functions: it can manufacture complete monolithic casings, create multi-material structures, and produce complex geometries that would require multiple parts in conventional manufacturing. This multi-functionality increases productivity by eliminating the need for separate manufacturing processes for different components.
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 cost-effective, efficient production of casings with uniform or varied metal properties, reducing thermal distortions and enabling rapid prototyping with improved mechanical integrity and design freedom, suitable for various warhead applications.
Implementation Method 1
cold-gas dynamic spraying of metal particles onto a support member
Data Source
AI summary
An embodiment of the bomb casing (1) defines a generally conical nose portion (2) and a cylindrical body portion (3). At least one, and more preferably both, of the generally conical nose portion (2) and/or the cylindrical body portion (3) are formed from an additive manufacturing process, which is preferably cold-gas dynamic spraying of metal particles onto a support member. In one embodiment, the generally conical nose portion and cylindrical body portion are integrally formed.