Nozzle Abrasion Resistance via Ceramic Pipe Segmentation
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Solution Overview
Problem
The cold spraying method faces issues with abrasion on the inner wall surface of the nozzle passage, which can alter the flow of the working gas and affect the film deposited on the substrate, and existing solutions do not adequately address this problem while also being cost-effective.
Innovation Solution
A film deposition apparatus with a nozzle design that includes a ceramic pipe in the region prone to abrasion, combined with a stainless steel pipe, where the ceramic pipe is limited to the area where abrasion is most likely to occur, reducing manufacturing costs and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire nozzle is made of a hard material such as ceramic material to suppress abrasion, then abrasion resistance is improved, but the manufacturing cost of the nozzle becomes expensive
Solution Approach 1:
The patent applies local quality by making only the upstream portion of the nozzle (where abrasion most occurs) of ceramic material, while the downstream portion remains metal. This localized application of hard material suppresses abrasion in the critical region without requiring the entire nozzle to be expensive ceramic, thus resolving the contradiction between abrasion resistance and manufacturing cost.
Solution Approach 2:
The nozzle is segmented into two distinct material zones: a ceramic upstream portion for abrasion resistance and a metal downstream portion for cost-effectiveness and ease of manufacture. This segmentation allows each portion to be optimized for its specific functional requirements while balancing overall performance and cost.
2Duration of action of stationary object
If the entire nozzle is made of a hard material such as ceramic material to suppress abrasion, then durability is improved, but high-precision machining and polishing are required which increases manufacturing complexity
Solution Approach 1:
By limiting ceramic material to only the upstream portion where durability is most critical, the patent reduces the overall manufacturing complexity compared to making the entire nozzle from ceramic. The metal downstream portion requires less precise machining, simplifying the overall manufacturing process while maintaining durability where needed.
3Reliability
If a ceramic pipe is used in the region prone to abrasion, then abrasion suppression is improved, but the manufacturing cost increases compared to using only metal
Solution Approach 1:
The patent implements local quality by positioning the ceramic pipe specifically in the upstream portion of the nozzle where abrasion occurs, rather than using ceramic throughout. This localized approach provides effective abrasion suppression in the critical region while minimizing the amount of expensive ceramic material required, thus reducing overall manufacturing cost.
Solution Approach 2:
The nozzle is segmented into a ceramic upstream section for abrasion suppression and a metal downstream section for cost-effectiveness. This segmentation strategy provides targeted protection where needed while avoiding unnecessary use of expensive materials in regions where they are not required, resolving the cost-performance trade-off.
Data Source
AI summary
The film deposition apparatus used in a thermal spraying method includes a spray gun which includes a nozzle, a powder supply unit that supplies a powder to the spray gun as a film deposition raw material, and a gas supply unit that supplies a working gas to the spray gun. The nozzle includes a stainless pipe as a nozzle pipe, a ceramic pipe connected to an upstream portion of the stainless pipe through which the working gas flows, and a nozzle holder into which the ceramic pipe is inserted. The nozzle holder includes a first portion extending in a first direction in which the working gas flows through the nozzle holder. The film deposition apparatus further includes a pipe which connects the powder supply unit and the first portion. A portion of the pipe, which is connected to the first portion, extends in a second direction intersecting the first direction.