Ni-Based Alloy Repair Coating Using Cold-Sprayed Superalloys

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Solution Overview

Problem

Gas turbine engine components, particularly those made of nickel-based superalloys, require improved repair methods as thermal spray coatings result in high porosity and debited properties, necessitating surface preparation and leading to increased maintenance costs and waste.

Innovation Solution

The cold spray process is used to deposit a coating with a mixture of Ni-based and Co-based superalloy particles at sub-melting point temperatures, forming a dense, wear-resistant, and fatigue-resistant layer without significant oxidation, directly onto untreated surfaces, reducing the need for surface preparation and enhancing the component's lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If thermal spray coating is used to repair Ni-based alloy components, then coating deposition is achieved, but high porosity and degraded properties result

Engineering Contradiction:

Improvecoating densityVSAvoidcoating quality

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent changes the temperature parameter by using cold spray technology to deposit particles at temperatures below their melting point, unlike thermal spray methods. This parameter change results in denser coatings with fewer defects and improved mechanical properties while maintaining adequate adhesion

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal energy-based deposition mechanism with a kinetic energy-based mechanism. Particles are accelerated to high velocities and deposited through mechanical impact and deformation, eliminating the thermal processes that cause porosity and oxidation in traditional thermal spray methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If surface preparation is performed before thermal spray coating, then coating adhesion is improved, but maintenance time and cost increase

Engineering Contradiction:

Improvecoating adhesionVSAvoidmaintenance time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The cold spray process inherently creates strong mechanical interlocking and metallurgical bonding through high-velocity particle impact and deformation. The process self-generates adequate surface preparation through the kinetic energy of the particles, eliminating the need for separate surface preparation steps while maintaining strong adhesion

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If thermal spray coating is applied, then coating deposition is achieved, but oxidation and waste material increase

Engineering Contradiction:

Improvecoating depositionVSAvoidoxidation and waste

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The cold spray process operates in an inert or controlled atmosphere at low temperatures, preventing oxidation of the Ni-based alloy particles during deposition. This eliminates the harmful oxidative effects while maintaining effective coating deposition

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

By changing the temperature parameter to sub-melting conditions, the patent prevents thermal oxidation that occurs in thermal spray processes. The lower temperature parameter eliminates the thermal degradation and oxidation pathways while maintaining deposition effectiveness through kinetic energy

Inventive Principle:

Principle #35Parameter changes

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 cold spray method extends the component's lifespan, reduces maintenance and scrap materials, and enhances wear resistance, resulting in longer operational life and lower maintenance costs by forming a strong, dense coating with tailored hardness.

Implementation Method 1

The cold spray process is used to deposit a coating with a mixture of Ni-based and Co-based superalloy particles at sub-melting point temperatures

Methodology Applied

Scientific EffectCold spray deposition: Deposition (physical)

Implementation Method 2

forming a dense, wear-resistant, and fatigue-resistant layer without significant oxidation, directly onto untreated surfaces

Methodology Applied

Scientific EffectKinetic energy deposition: Impact Force

Data Source

PatentUS20250101598A1Methods of altering a surface of a ni-based alloy and resulting components

Publication Date: 2025.03.27 GENERAL ELECTRIC CO

AI summary

Method of repairing a Ni-based alloy component are provided, along with the resulting repaired coated component. The method may include: spraying a plurality of particles onto a surface of the Ni-based alloy component to form a coating thereon. The plurality of particles comprises a mixture of Ni-based superalloy particles and Co-based superalloy particles. The particles are sprayed at a spray temperature that is less than a melting point of both the Ni-based superalloy particles and the Co-based superalloy particles. A repaired coated component may include: a Ni-based alloy component having a surface and a coating on the surface of the Ni-based alloy component. The coating comprises a plurality of deformed particles therein, with the plurality of deformed particles comprises 5% by weight to 80% by weight of a Ni-based superalloy and 20% by weight to 95% by weight of a Co-based superalloy.