Cold-Sprayed External Pressure Vessels for Deep-Sea Corrosion Resistance
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Solution Overview
Problem
Conventional submersible vehicles require long lead times and expensive materials to construct large pressure vessels that can withstand high pressures and resist seawater corrosion, hindering project efficiency and increasing costs.
Innovation Solution
The development of external pressure vessels with a densified cold spray structure, manufactured through a process involving rotating a mandrel, cold spraying metallic powder, heat treating, and hot isostatic pressing, to enhance structural rigidity and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional steel or aluminum forgings are used to construct pressure vessels, then the vessels can withstand high pressures and resist corrosion, but the production time takes up to 36 months and costs are expensive
Solution Approach 1:
The patent changes the manufacturing parameters from conventional forging processes to cold spray deposition followed by heat treatment and hot isostatic pressing. This transforms the production approach from months-long forging cycles to a streamlined process completing in significantly less time while maintaining the required pressure and corrosion resistance properties through controlled material deposition and densification parameters
Solution Approach 2:
The patent employs composite material construction by depositing metallic powder layers that are subsequently heat-treated and hot isostatically pressed to create a dense, multi-layered structure. This composite approach combines the benefits of different materials and processing stages to achieve high strength-to-weight ratio, corrosion resistance, and pressure withstand capability without the extended lead times of traditional forging
2Reliability
If conventional steel or aluminum forgings are used to construct pressure vessels, then the vessels can withstand high pressures and resist corrosion, but the manufacturing cost is high
Solution Approach 1:
The patent modifies manufacturing parameters by replacing expensive conventional forging processes with cold spray deposition followed by heat treatment and hot isostatic pressing. This parameter change reduces material waste, eliminates costly forging equipment requirements, and shortens production cycles, thereby significantly lowering manufacturing costs while preserving the essential pressure and corrosion resistance properties
Solution Approach 2:
The patent substitutes the conventional mechanical forging system with a deposition-based manufacturing system. Instead of using heavy forging presses and complex tooling, the invention uses cold spray deposition technology followed by thermal and pressure treatment, replacing expensive mechanical forging infrastructure with more cost-effective deposition and heat treatment equipment
3Volume of moving object
If the size of the pressure vessel structure increases, then the vessel can accommodate larger internal volumes, but the manufacturing difficulty and cost increase exponentially
Solution Approach 1:
The patent applies segmentation by constructing large pressure vessels through sequential deposition of metallic powder layers around a mandrel. Instead of forging the entire large structure in one piece, the vessel is built up layer by layer, allowing modular construction that scales linearly with size rather than exponentially, thereby reducing manufacturing complexity for larger internal volumes
Solution Approach 2:
The patent uses a mandrel as a preliminary structure around which the pressure vessel is constructed. This preliminary action allows the vessel to be built up in controlled layers, making large-volume vessels manageable through systematic deposition processes rather than attempting to forge or form entire large structures in one operation, thus reducing manufacturing complexity
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 method significantly reduces production time and cost while providing pressure vessels capable of withstanding high pressures and resisting seawater corrosion, ensuring the structural integrity and protection of internal components.
Implementation Method 1
cold spraying a metallic powder onto the mandrel to yield a first intermediate product
Implementation Method 2
hot isostatic pressing the third intermediate product
Implementation Method 3
cold spraying a metallic powder onto the mandrel to yield a first intermediate product
Implementation Method 4
heat treating the second intermediate product to yield a third intermediate product
Data Source
AI summary
An external pressure vessel including a wall defining an enclosed internal volume, wherein at least a portion of the wall includes a densified cold spray structure.