Cold Sprayed Smart Susceptor for Induction Heating

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Solution Overview

Problem

Existing induction heating systems using thermal spraying of magnetically permeable powders are limited by oxidation, geometrical shape constraints, and dimensional tolerances, which restrict the composition and stability of susceptors.

Innovation Solution

Cold spraying ferromagnetic materials onto pre-formed tooling components with incremental sheet forming allows for the creation of smart susceptors with desired Curie temperatures and geometries, enabling more versatile and durable heating solutions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal spraying of magnetically permeable powder is used to form a susceptor, then the susceptor can be formed with magnetic properties, but the powder composition is limited and oxidation occurs

Engineering Contradiction:

Improvesusceptor stabilityVSAvoidpowder composition range

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the temperature parameter of the spraying process from high temperature (thermal spraying) to low temperature (cold spraying). This parameter change allows the use of a wider range of ferromagnetic powder compositions without melting or oxidation, while still forming a functional susceptor coating on the mesh structure.

Inventive Principle:

Principle #35Parameter changes

2Strength

If thermal spraying is used to apply magnetically permeable powder, then the powder is melted and bonded, but oxidation of the sprayed susceptor occurs

Engineering Contradiction:

Improvepowder bondingVSAvoidoxidation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent employs cold spraying technology that operates at temperatures below the melting point of the ferromagnetic powder, creating an environment that prevents oxidation. The process uses compressed gas to accelerate powder particles without thermal exposure, thereby eliminating oxidation while maintaining effective bonding through kinetic energy impact.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Ease of manufacture

If a mesh structure is used as the substrate for spraying powder, then the susceptor can be formed, but the geometrical shape is limited and dimensional tolerances are poor

Engineering Contradiction:

Improvesusceptor formationVSAvoiddimensional tolerances

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies cold sprayed ferromagnetic powder to a pre-formed mesh structure that has already been shaped to the desired geometrical configuration. The mesh structure serves as a pre-prepared substrate with controlled dimensions, allowing the susceptor to achieve both ease of manufacture through modular assembly and improved dimensional tolerances through precise pre-forming of the mesh components.

Inventive Principle:

Principle #10Preliminary action

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 enhances the durability and dimensional accuracy of smart susceptors, allowing for a wider range of ferromagnetic materials and improved thermal stability, while avoiding oxidation and geometrical limitations.

Implementation Method 1

The heater positioned along the first line may heat the gas in the first line to between approximately 400 degrees Celsius to 900 degrees Celsius

Methodology Applied

Scientific EffectGas heating: Heating

Implementation Method 2

cold spraying a ferromagnetic material cold on to a surface of a tool that may previously be formed into a desired shape by increment sheet forming

Methodology Applied

Scientific EffectCold spray deposition: Deposition (physical)

Implementation Method 3

an induction coil capable of generating an oscillating electromagnetic field and a susceptor positioned in the oscillating electromagnetic field when said induction coil is energized

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 4

applying an oscillating electromagnetic field to the smart susceptor to generate eddy currents to heat the smart susceptor

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Data Source

PatentUS9635714B2Incremental sheet forming for fabrication of cold sprayed smart susceptor

Publication Date: 2017.04.25 THE BOEING CO

AI summary

An induction heating system for manufacturing a part including an induction coil and a smart susceptor positioned within an oscillating electromagnetic field from the induction coil. The smart susceptor includes a ferromagnetic material cold sprayed onto a tool. The tool may be a sheet metal component formed to a desired shape by incremental sheet forming. The smart susceptor may be heated up by eddy currents generated in the ferromagnetic material by the oscillating electromagnetic field. The smart susceptor may be designed to have a desired Curie temperature based on the composition of the ferromagnetic material. The smart susceptor is formed into a desired shape by cold spraying ferromagnetic material onto a tool already formed into the desired shape. The smart susceptor may be removed from the tool by thermally shocking the smart susceptor and the tool and may be used to heat a part to be formed.