A process for joining dissimilar materials. The process includes providing a first component made from a first material and a second component made from a second material. The process also includes cold spraying a bead of the second material onto the first component and joining the second component to the bead on the first component such that a weldment is formed from the first component and the second component. In some instances, joining of the second component to the bead on the first component is performed by fusion welding the bead and the second component together.

Method to join dissimilar materials by the cold spray process

An atomizing spray device includes a housing having plural inlets and one or more outlets fluidly coupled with each other by an interior chamber. The inlets include a first inlet shaped to receive a first fluid and a second inlet shaped to receive a slurry of ceramic particles and a second fluid. The interior chamber in the housing is shaped to mix the first fluid received via the first inlet with the slurry received via the second inlet inside the housing to form a mixture in a location between the inlets and the one or more outlets. The interior chamber in the housing also is shaped to direct the mixture formed inside the housing as droplets outside of the housing via the one or more outlets such that, based on a discharged amount of the first fluid in the droplets, the first fluid promotes evaporation of the second fluid as the droplets traverse from the housing toward a surface of a component.

Coating system and method

An improved gas dynamic cold spray device according to our invention can deposit a wide variety of materials on a variety of substrates. It comprises of a control panel (1), which is connected to a spray gun (2) provided with a converging diverging nozzle (9) by virtue of which supersonic velocities are realized causing the deposition of the material at an overall optimal power and gas consumption without use of any powder preaheater, stencils, flow regulators. Compressed gas supply (4) is provided to the control panel by flexible pneumatic hose (5). Pneumatic flexible hose (6,7) carrying the gas connects the control panel, spray gun, and the powder feeder (3). Powder feeder provides powder to the spray gun by means of carrier gas through pneumatic hose (7a) and powder feeding tube (15). The control panel is electrically connected to powder feeder and gas heater (11) by means of electric cables (13,8,12).

An improved gas dynamic cold spray device and method of coating a substrate

The invention relates to a device for feeding a powder into a fluid flow, with a dosing element (2), which can be driven in rotation in a storage volume (1) about an axis of rotation and has dosing chambers (3) open to the storage volume (1), wherein the dosing chambers (3) are filled with the powder (4) stored in the storage volume during the rotation of the dosing element (2) and are emptied into the fluid flow at an emptying point. The powder (4) is moved by means of an agitator (11) arranged and driven in rotation in the storage volume (1). The wall (5) of the storage volume (1) is assigned movement influencing means (6, 16), with which the movement of an agitator arm (12) or an actuation extension (13) fastened to the agitator arm (12) is influenced in such a way that a radial and/or axial movement deflection of the agitator arm (12) or the actuation extension (13) are/is brought about.

Device for controlled dispensing of a powder

An additively manufactured attritable engine (100) includes a compressor section, a combustion section, a turbine section, and an engine case wall (102, 104), which surrounds the compressor section, the combustion section, and the turbine section. The engine case wall (102, 104) includes a first cavity embedded in the engine case wall (102, 104) that defines an injector (120) that is in fluid communication with the combustion section. The engine case wall (102, 104) includes a second cavity embedded within the engine case wall (102, 104) and defines a fuel feed passage (116) that is in thermal communication through the exterior surface (150) of the engine case wall (102, 104).

Fuel feed passages for an attritable engine

A powder feeder for a cold spray system includes a rotatable drum body, a housing surrounding the drum body, and a support structure. The support structure couples to the housing and supports the housing such that the drum body rotates about a rotation axis to provide in-situ blending of powder disposed within an interior of the drum body.

Cold spray powder feeders with in-situ powder blending

A portable gas heater includes a housing, a pressure vessel arranged in the housing, a layer of thermal insulation disposed on an interior wall of the pressure vessel, a heating element arranged within the layer of thermal insulation, and a gas diffuser arranged upstream from the heating element. A cold spray system including the portable gas heater and a method of heating gas are also disclosed.

High temperature and high pressure portable gas heater

An attritable engine (100) includes an engine case (105), which includes an outer wall (110) and a fuel rail (120) integral with the outer wall (110). The fuel rail (120) includes a fuel line (121) integral with the outer wall (110), a fuel ring (124) configured to receive fuel from the fuel line (121), and an injector throat (126) configured to receive aerated fuel from the fuel ring (124). The engine case (105) includes counter distortion webbing (130) defining the injector throat (126) and is integral with the fuel rail (120) and the outer wall (110). The engine case (105) includes a combustion chamber (140) configured to receive fuel from the injector throat (126).

Integrated fuel injectors for attritable engines and additive manufacturing method

A component for a gas turbine engine is disclosed. In various embodiments, the component includes a diffuser ring, a combustor and a spring element connecting the diffuser ring to the combustor.

Additive integral combustor expansion spring

A unitary rub strip comprises a casing having an inner surface and an outer surface opposite the inner surface; a unitary rub strip is formed integral with the casing proximate the inner surface, wherein the unitary rub strip comprises a modified structure within the casing configured to abrade responsive to an interaction with a rotating element.

Kennedy Matthew B

Papers

Cold spray powder feeders with in-situ powder blending

High temperature and high pressure portable gas heater

Integrated fuel injectors for attritable engines and additive manufacturing method

Additive integral combustor expansion spring

Additively manufactured rub-strip, casing with integrated rub-strip and process for forming the casing