Source: https://patents.google.com/patent/US9095932B2/en
Timestamp: 2018-07-18 19:06:55
Document Index: 664408906

Matched Legal Cases: ['Application No. 2', 'Application No. 2007800364699', 'Application No. 07843733', 'Application No. 09813462', 'Application No. 09813462', 'Application No. 2010', 'Application No. 2011', 'Application No. 2009', 'Application No. 2009', 'Application No. 10', 'Application No. 09813462', 'Application No. 13184639', 'Application No. 14166073', 'Application No. 09172234']

US9095932B2 - Methods of joining metallic protective layers - Google Patents
US9095932B2
US9095932B2 US14293643 US201414293643A US9095932B2 US 9095932 B2 US9095932 B2 US 9095932B2 US 14293643 US14293643 US 14293643 US 201414293643 A US201414293643 A US 201414293643A US 9095932 B2 US9095932 B2 US 9095932B2
US14293643
US20140311669A1 (en )
In various embodiments, protective layers are bonded to a steel layer, overlapped, and at least partially covered by a layer of unmelted metal powder produced by cold spray.
This application is a continuation of U.S. patent application Ser. No. 13/848,404, filed on Mar. 21, 2013, which is a continuation of U.S. patent application Ser. No. 13/343,113, filed on Jan. 4, 2012, now U.S. Pat. No. 8,448,840, which is a continuation of U.S. patent application Ser. No. 13/184,665, filed on Jul. 18, 2011, now U.S. Pat. No. 8,113,413, which is a continuation of U.S. patent application Ser. No. 11/638,625, filed on Dec. 13, 2006, now abandoned, the content of each of which is incorporated by reference herein in its entirety.
Cold spray or kinetic spray (see U.S. Pat. Nos. 5,302,414, 6,502,767 and 6,759,085) is an emerging industrial technology that is being employed to solve many industrial manufacturing challenges (see, e.g., U.S. Pat. Nos. 6,924,974, 6,444,259, 6,491,208 and 6,905,728). Cold spray employs a high velocity gas jet to rapidly accelerate powder particles to high velocity such that when they impact a surface the particles bond to the surface to form an integral, well bonded and dense coating. The cold spraying of tantalum powders onto a variety of substrates (including steel) has been suggested (see, e.g., “Analysis of Tantalum Coatings Produced by the Kinetic Spray Process,” Van Steenkiste et al, Journal of Thermal Spray Technology, volume 13, number 2, June 2004, pages 265-273; “Cold spraying—innovative layers for new applications,” Marx et al, Journal of Thermal Spray Technology, volume 15, number 2, June 2006, pages 177-183; and “The Cold Spray Process and Its Potential for Industrial Applications,” Gärtner et al, Journal of Thermal Spray Technology, volume 15, number 2, June 2006, pages 223-232). This is all accomplished without having to heat the tantalum powder to a temperature near or above its melting point as is done with traditional thermal spray processes. The fact that dense coatings can be formed at low temperatures present many advantages. Such advantages include reduced oxidation, high density deposits, solid state compaction, the lack of thermally induced stresses and particularly, in this case, the lack of substrate heating. This is critical because at elevated temperatures, such as in a molten Ta weld pool, Ta can dissolve the elemental components of steels and stainless steels with the result that brittle and non corrosion resistant phases form in the tantalum.
Because the cold spray process is done at low temperatures, there is no harmful dissolution of the steel into the cold sprayed tantalum joint. The tantalum joint is fully dense with no porosity or oxygen pick up which would impair the joints performance. Furthermore, there are no thermally induced stresses at the joint after fabrication that could lead to separation, buckling or cracking. Stress is an issue with all high temperature joining processes due to the large differences in thermal expansion between tantalum (LCTE=6.5×10−6 cm (cm ° C.)−1 and steel (LCTE=11.7×10−6 cm (cm ° C.)−1 In fact to completely eliminate thermal stress during operation, the spraying could be done while the components are held at operational temperatures of less than 250° C.
1. A method of joining protective cladding layers over an underlying steel layer without the use of batten strips, the method comprising:
bonding a first protective layer to an underlying steel layer at an interface between the first protective layer and the steel layer;
bonding a second protective layer to the steel layer at an interface between the second protective layer and the steel layer, the steel layer underlying the second protective layer;
disposing a portion of the first protective layer over a portion of the second protective layer, thereby forming a region of overlap; and
thereafter, and without otherwise bonding the first protective layer to the second protective layer in the region of overlap, cold spraying a metal powder over and in contact with the first and second protective layers in the region of overlap to form a layer of unmelted metal powder that directly connects the first and second protective layers.
8. The method of claim 7, wherein bonding both of the first and second protective layers to the steel layer comprises at least one of diffusion bonding or explosive bonding.
9. The method of claim 1, wherein at least one of the first or second protective layers is bonded to the steel layer via a structural adhesive, a low-temperature brazing material, or a low-temperature solder.
10. The method of claim 9, wherein the at least one of the first or second protective layers is bonded to the steel layer via a structural adhesive having a decomposition temperature less than approximately 300° C.
11. The method of claim 9, wherein the at least one of the first or second protective layers is bonded to the steel layer via a low-temperature solder having a melting point less than approximately 400° C.
12. The method of claim 1, wherein bonding the second protective layer to the underlying steel layer comprises cold spraying the second protective layer over the steel layer.
13. The method of claim 1, wherein a thickness of at least one of the first or second protective layers ranges between approximately 0.005 inches and approximately 0.02 inches.
14. The method of claim 1, wherein a thickness of at least one of the first or second protective layers ranges between approximately 0.005 inches and approximately 0.01 inches.
15. The method of claim 1, wherein the layer of unmelted metal powder comprises elongated particles having a random crystallographic orientation.
16. The method of claim 1, wherein the layer of unmelted metal powder has a density greater than approximately 95%.
17. The method of claim 16, wherein the layer of unmelted metal powder has a density greater than approximately 97.5%.
18. The method of claim 1, further comprising annealing the layer of unmelted metal powder for at least one of relieving mechanical stress or improving interparticle bond strength.
19. The method of claim 18, wherein the annealing recrystallizes at least a portion of the layer of unmelted metal powder.
20. The method of claim 18, wherein the annealing is performed at a temperature greater than approximately 1150° C.
21. The method of claim 1, wherein the steel layer comprises stainless steel.
22. The method of claim 1, wherein after cold spraying the layer of unmelted metal powder and the first and second protective layers are substantially free of impurities diffused therein from the steel layer.
23. The method of claim 1, further comprising, prior to forming the region of overlap, joining two steel members to form the underlying steel layer, thereby forming a joint, wherein the region of overlap is disposed proximate the joint.
24. The method of claim 23, wherein joining the two steel members comprises welding.
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US14293643 US9095932B2 (en) 2006-12-13 2014-06-02 Methods of joining metallic protective layers
US13848404 Continuation US8777090B2 (en) 2006-12-13 2013-03-21 Methods of joining metallic protective layers
US20140311669A1 true US20140311669A1 (en) 2014-10-23
US9095932B2 true US9095932B2 (en) 2015-08-04
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US14293643 Active US9095932B2 (en) 2006-12-13 2014-06-02 Methods of joining metallic protective layers
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