Multi-angle Cold Spray Nozzle Assembly for Complex Surface Coating
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Solution Overview
Problem
Conventional cold spray nozzle arrangements result in weak bonding of coating particles at their side portions due to perpendicular impact, leading to potential coating failure on complex surfaces.
Innovation Solution
A multi-angle cold spray nozzle assembly comprising a primary spray nozzle and two or more secondary spray nozzles, positioned to deposit powder material at varying angles, ensuring optimal distribution of impact energy for enhanced bonding across the surface, including coplanar secondary nozzles to improve side bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-angle nozzle assembly is used to improve side bonding, then the device complexity increases
Solution Approach 1:
The multiple nozzles are designed to work together as a unified spray assembly that can be positioned and oriented as a single unit. The nozzles share common support structures, positioning mechanisms, and control systems, allowing them to function collectively while providing multi-angle deposition capability. This reduces the operational complexity compared to having entirely separate spray systems.
Solution Approach 2:
Multiple nozzles that would otherwise be separate devices are merged into a single integrated spray assembly. They share common mounting structures, positioning mechanisms, and control systems, reducing the overall complexity of handling and operation compared to using multiple independent spray systems.
2Ease of manufacture
If perpendicular impact is used for coating deposition, then the manufacturing process is simple, but the coating reliability deteriorates due to weak side bonding
Solution Approach 1:
The spray process is segmented into multiple simultaneous deposition streams from different nozzles, each targeting specific regions of the coating particle with optimized impact angles. This segmentation allows the process to maintain simplicity through integrated control while achieving reliable bonding across the entire particle surface.
Solution Approach 2:
The coating process applies different impact angles to different regions of the particle based on their specific bonding requirements. This local optimization ensures that each region of the coating particle achieves adequate bonding strength, thereby improving overall coating reliability while maintaining process efficiency through simultaneous deposition.
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
Enables efficient coating deposition on complex geometries with improved bonding strength, reducing the likelihood of weak bonding and enhancing the durability of the coating layer.
Implementation Method 1
a high pressure (4 to 5 MPa) and preheated (up to 1000° C.) gas stream (for example, nitrogen or helium) to accelerate micro-particles (15 to 60 μm diameter) via a converging-diverging nozzle (de Laval) to supersonic speeds
Implementation Method 2
accelerate micro-particles (15 to 60 μm diameter) via a converging-diverging nozzle (de Laval) to supersonic speeds (approximately 600 to 1000 m/s)
Implementation Method 3
The micro-particles will then plastically deform, undergo rapid interfacial melting and bond with the substrate, forming the coating
Implementation Method 4
perpendicular impact converts the maximum proportion of the kinetic energy of the particle to thermal bonding
Data Source
AI summary
A Cold spray nozzle assembly for depositing powder material onto a component surface includes a primary spray nozzle, two or more secondary spray nozzles, and a support mechanism supporting each spray nozzle. Each spray nozzle deposits powder material on a single target point on the surface, a reference plane being defined normal to a surface plane at the target point. The primary nozzle is in a primary plane that is normal to the surface plane, and that defines a primary dihedral angle with the reference plane. An axis of the primary nozzle defines a primary nozzle angle with the surface plane. Each of the secondary spray nozzles is in a corresponding secondary plane, with each being normal to the surface plane and defining a respective secondary dihedral-angle with the reference plane. An axis of each secondary spray nozzle defines a respective secondary nozzle angle with the surface plane.