Patent Description:
Without remediation, when spraying without a gas recovery booth gas used in CSAM is lost after a single use. Further, in some cases, the gas flies close to the substrate of the part that is subject to CSAM and is thus even more difficult to recover. Thus, in contemporary pre-existing cold spray implementations, cold spraying in an open environment (e.g., an airplane repair hangar) is completely non-viable, being too complex and expensive. And, no open environment cold spray gas recovery system exists.

Currently available CSAM-based part repair solutions use cold spray in a booth incorporating a gas recovery system to recapture the used gas for purification and reuse. This limits the applicability of cold spray to disassembled components that fit within the booth. Booth-based solutions have limited technological impact and restricted commercial application. Damaged parts must be disassembled, shipped to a repair facility, repaired in a booth, shipped back to the point of origin, and reassembled. The booth-based process is inefficient, expensive, and introduces multiple vectors for new damage to parts, requiring further costly repair or replacement. Current supersonic CSAM is also loud, causing disruption and often requiring hearing protection when in operation.

<CIT>, in accordance with its abstract, states an environmentally compliant triboelectric applicator and process for coating or ablating a substrate and for retrieving excess or ejected material from the substrate. The applicator comprises an inner supersonic nozzle for accelerating triboelectrically charged projectile particles entrained in a supersonic gas to speeds sufficiently high to coat or ablate a substrate and an outer evacuator nozzle coaxially surrounding the inner supersonic nozzle for retrieving excess projectile particles, ablated substrate powders, or other environmentally hazardous materials. A fluid dynamic coupling uses the efficacy of the Mach turning angle associated with a supersonic boundary layer of carrier gas to aspirate the central core of the supersonic two-phase jet. This fluid coupling and spacing between the outlet of the supersonic nozzle and the substrate also permits the projectile particles and substrate to triboelectrically charge to levels which induce electrostatic discharges at the substrate simultaneous to the impacts.

<CIT>, in accordance with its abstract, states that a cold spray system includes a spray nozzle for depositing material onto a substrate. A collection assembly at least partially surrounds the spray nozzle for vacuuming undeposited material and gases in the work area. The collection assembly includes a transparent collection tube at an end portion of the collection assembly to provide visibility to the work area. The collection assembly includes a shield having a flange that extends radially outwardly from the collection assembly and is generally parallel to a substrate. An angled portion of the shield extends from the collection assembly. A radius portion adjoins the flange and the angled portion. A ring is spaced between the spray nozzle and the shield. An inner surface of the ring deflects material that typically would otherwise not become adhered to the substrate back into the collection assembly to minimize the material that must be vacuumed at the substrate. A curved surface of the ring extends from a surface spaced from the substrate toward the shield to provide a smooth transition for materials flowing along the substrate back into the collection assembly.

<CIT>, in accordance with its abstract, states limitations with methods, systems and processes for integrating multiple advanced technologies into a single automated manufacturing and repair cell. The methods, systems and processes of WO' <NUM> A1 leverage unique software and hardware to configure a manufacturing cell that is capable of conducting process development and planning, dimensional analysis, pre-machining, surface preparation, cold spray (supersonic particle deposition), dust collection, helium recovery, and post machining in a single integrated manufacturing and repair cell.

According to the present disclosure, a gas recovery nozzle and a method for performing cold spray additive manufacturing as defined in the independent claims are provided. Further embodiments of the claimed invention are defined in the dependent claims. Although the claimed invention is only defined by the claims, the below embodiments, examples, and aspects are present for aiding in understanding the background and advantages of the claimed invention.

There is provided a gas recovery nozzle as defined in claim <NUM>.

Further, there is provided a method for performing cold spray additive manufacturing in accordance with claim <NUM>.

The foregoing Summary, as well as the following Detailed Description of certain implementations, will be better understood when read in conjunction with the appended drawings.

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings, wherein:.

Corresponding reference characters indicate corresponding parts throughout the drawings in accordance with an implementation.

Cold spray additive manufacturing (also "cold spray" or "CSAM" herein) is a material-deposition process where metal or metal-ceramic mixtures of powders (also referred to as "particles" herein) suspended in a gas propelled at supersonic speed are used to form a coating or freestanding structure. Specifically, cold spraying is defined herein as spraying a material at a temperature that is below the melting point of the material being sprayed. CSAM is a solid state process: neither the powders nor the substrate to which the powders are applied are melted during the process. Thus, use of CSAM provides material-deposition that does not cause thermally induced alterations to the substrate or powder (e.g., deformation, crystallization, imperfections, or other types of damage). Due to the direct impingement of the gases carrying the powders upon the substrate, cold spray generates a stationary shock wave and also a lateral flow of gas along the surface of the part subject to CSAM.

As used herein, a stationary shock wave in the context of the flow of supersonic gas (also called a "stationary normal shock wave") is a discontinuity that forms in order for the flow to meet some downstream condition (e.g., an obstacle or back pressure). When the back pressure becomes too great, the flow of gas cannot achieve supersonic speeds and is compressed at the nozzle before expanding. The presence of stationary shock waves thus detracts from optimal supersonic gas flow in CSAM systems and methods. Implementations of the disclosure also mitigate such stationary shock waves.

High- and low-pressure cold spray is an emerging technology finding increasing applications in various types of structural repairs. In some implementations, cold spray is usable to repair metallic structures (e.g., airplane or helicopter components). A closer examination of an implantation of a CSAM apparatus and process is provided in the discussion of <FIG> herein.

Referring to the figures, implementations of the disclosure include systems and methods for cold spray additive manufacturing with gas recovery that provide a superior cost/benefit ratio in comparison to conventional cold spray implementations. Recapturing and reusing the gas enables potentially large cost savings and renders cold spray additive manufacturing far more commercially viable and efficient. The various implementations not only allow for the reuse of the gas, but also enable cold spray additive manufacturing to occur in situ in an open environment (e.g., repairs on an airplane in an airplane hangar). Because no cold spray booth is required, the implementations completely avoid the need for disassembly, shipping a damaged part to a repair facility, conducting repairs in a booth fitted with a gas recovery system, shipping back to the point of origin, and reassembly. Comparatively, conducting cold spray additive manufacturing -based repairs in situ in an open environment is efficient, far less expensive, and avoids entirely multiple vectors for new damage to parts involved in contemporary pre-existing cold spray processes as well as the associated follow-up costly repairs or replacements.

The elements described herein in various implementations operate in an unconventional manner to provide systems and methods for cold spray additive manufacturing with gas recovery by utilizing a gas recovery nozzle. Implementations of the gas recovery nozzle are configured to attach to a supersonic nozzle used to conduct cold spray additive manufacturing. The gas recovery nozzle captures a lateral flow of gas from a part under repair and circulates the gas to a gas recovery sub-system. The gas recovery nozzle accomplishes this by creating an envelope over the supersonic nozzle that captures at least some of the gas that is deflected laterally on impact with the part under repair during cold spray additive manufacturing. The captured gas is circulated to the gas recovery sub-system. The gas recovery sub-system collects the captured gas into storage devices for later treatment (e.g., purification) and reuse in future cold spray additive manufacturing processes.

Some implementations of the gas recovery nozzle further comprise a flexible coupling to control the standout distance from the gas recovery nozzle to the substrate of the part. Maintaining an efficient standout distance between the gas recovery nozzle and the substrate of the part: (<NUM>) prevents additive particles from clogging either the supersonic nozzle or the gas recovery nozzle, allowing for a higher sustained rate of gas recovery per unit time; (<NUM>) prevents a stationary shock wave of the gas recovery nozzle from interfering with a supersonic flow of gas; (<NUM>) focuses or redirects the supersonic flow of gas in a useful and beneficial way; and (<NUM>) provides an adequate sealing that increases the gas capture rate. Effects of various standout distances on various implementations of the disclosure are discussed elsewhere herein. Further, the gas recovery nozzle acts as a suppressor for the supersonic nozzle, significantly reducing the very high decibel noise, and the associated disruption (e.g., from hearing damage or an inability to hear shouted warnings in a work area), typical of cold spray additive manufacturing solutions. In some implementations, the flexible coupling is a single component; in other implementations the flexible coupling is a mechanism with more than one component. Multi-part flexible couplings include but are not limited to flexible couplings assembled using petal joins.

The implementations of the present disclosure are thus superior to typical implementations of cold spray additive manufacturing systems and methods that fail completely to capture and reuse gas when repairs are conducted in situ without disassembly and use of a repair booth. The performance of implementations of the systems and methods for cold spray additive manufacturing with gas recovery disclosed herein, as measured by the ability to capture and reuse supersonically-propelled gas propelling particles onto a substrate, substantially equals and sometimes exceeds conventional existing contemporary systems and methods for cold spray additive manufacturing with gas recovery having designs that introduce inherent and unavoidable loss of supersonically-propelled gas.

The disclosure is thus mechanically more robust and more cost effective to implement, while at the same time being more effective than conventional systems and methods for cold spray additive manufacturing at both enabling reuse of supersonically-propelled gas and in-situ repairs.

Referring again to <FIG>, a cross-sectional side elevation view illustrates an implementation of a gas recovery nozzle <NUM> in accordance with an implementation. The gas recovery nozzle <NUM> comprises a main body <NUM> configured to attach to a supersonic nozzle <NUM> and a first end <NUM> having angled walls <NUM> at an opening <NUM> defining a gas flow path <NUM> from the supersonic nozzle <NUM>. In some implementations, a larger diameter opening is thereby defined at the distal end by an angled wall portion between laterally or longitudinally (e.g., straight) extending wall portions extending outward from a distal end of the supersonic nozzle. The first end <NUM> can take different shapes and configurations, such as having curved or arcuate walls that are continuously or gradually increasing or decreasing in curvature. That is, the present disclosure contemplates different conical shaped ends, or ends having different angled openings.

It should be noted that the first end <NUM> is illustrated as being located within the main body <NUM>. However, the first end <NUM> in some implementations extends to the end of the main body <NUM>. In various implementations the first end <NUM> is co-axial with the main body <NUM>.

The gas recovery nozzle <NUM> further comprises a passage <NUM> extending from the first end <NUM> to a second end <NUM>. The first end <NUM> is a distal end and the second end <NUM> is a proximal end relative to the supersonic nozzle <NUM>. The gas recovery nozzle <NUM> further comprises a cavity <NUM> surrounding the passage <NUM>. The cavity <NUM> is configured to collect at least some gas <NUM> expelled from the supersonic nozzle <NUM>. In some implementations, an open end <NUM> of the cavity <NUM> at a part side <NUM> comprises curved walls <NUM> (e.g., arcuate shaped). In some other implementations, the open end <NUM> of the cavity <NUM> extends farther distally than the opening <NUM> at the first end <NUM> (and has a greater diameter than the first end <NUM> such that a space is defined between a gas flow path having the opening <NUM>, and an inner surface of the main body <NUM>). That is, the conical shaped first end <NUM> is positioned concentrically within the main body <NUM> and does not extend to the open end <NUM>. The curved wall <NUM> is shaped and/or configured to facilitate capture of the expelled gas <NUM> after impinging on a part <NUM>.

In some implementations, the gas <NUM> comprises an at least one of Helium or Nitrogen gas. In some implementations including the supersonic nozzle <NUM>, Helium is the preferred gas <NUM>. In the supersonic nozzle <NUM>, the speed of the gas <NUM> correlates with the speed of sound and the Mach number of the gas <NUM>. For Helium, the speed of sound at standard atmospheric conditions is <NUM>/s (<NUM>/s). For Nitrogen, the speed of sound at standard atmospheric conditions is only <NUM>/s (<NUM>/s). This translates into higher particle velocities when Helium is used versus when Nitrogen is used. Thus, if cost and availability are not deciding factors (that is, if the disclosure herein is implemented such that the gas <NUM> is reusable across cold spray sessions), then Helium provides superior performance in CSAM applications versus Nitrogen.

The cavity <NUM> defines a gas recovery path <NUM> that leads to an outlet <NUM>. That is, the gas recovery nozzle <NUM> further comprises the outlet <NUM> within the main body <NUM> configured to connect to a gas recovery sub-system <NUM>. In some implementations, the outlet <NUM> comprises an opening <NUM> configured to connect to a compressor pump <NUM> of the gas recovery sub-system <NUM>. In some implementations including the compressor pump <NUM>, a gas diffuser <NUM> is provided at the opening <NUM> of the cavity <NUM>, which can be located inside, outside, or both inside and outside the cavity <NUM>. The gas diffuser is constructed of an open pore metallic foam (e.g., ALUPOR™ cast aluminum metallic foam) or any mechanically equivalent material or component (e.g., a RADNOR® <NUM> Series gas diffuser). The gas diffuser <NUM> is configured to slow the flow of the gas <NUM> inside the cavity <NUM> to the opening <NUM>. The gas diffuser <NUM> facilitates at least one of slowing the flow of gas <NUM> or directing the flow of gas <NUM> to the compressor pump <NUM>.

Other implementations replace or complement the compressor pump <NUM> with another suitable type of pump, a turbofan, or any other mechanically suitable mechanism configured to pull the gas <NUM> into the gas recovery sub-system <NUM>. In some other implementations, the outlet <NUM> comprises an opening <NUM> configured to connect to a movable gas recovery tank <NUM>. In some implementations, more than one moveable gas recovery tank <NUM> is connected to the opening <NUM>. In implementations including the moveable gas recovery tank <NUM>, the compressor pump <NUM>, other suitable type of pump, the turbofan, vacuum, or any other mechanically suitable mechanism configured to both intake the gas <NUM> into the gas recovery sub-system <NUM> is further configured to ensure that the greatest possible volume of the gas <NUM> is compressed into and stored in the moveable gas recovery tank <NUM>. Once the gas <NUM> is stored, the gas <NUM> is available for purification and reuse with suitable processes and apparatuses as described elsewhere herein (see, e.g., the discussion of <FIG>). In some implementations, purification includes removal of Oxygen and other matter that is not the gas <NUM>.

In some implementations, the main body <NUM> is tubular and configured to surround an end <NUM> of the supersonic nozzle <NUM> (not illustrated). In some other implementations, the main body <NUM> is configured as a removable cover <NUM> to capture a flow of gas <NUM> from the supersonic nozzle <NUM> and circulate the gas <NUM> to the gas recovery sub-system <NUM>. That is, the main body <NUM> is removably coupled to the supersonic nozzle <NUM>, which may include mechanical attachment (e.g., bolt or screw attachment to a portion of the base of the supersonic nozzle <NUM>) to secure the main body <NUM> thereto. That is, in some implementations, the gas recovery nozzle <NUM> is fixed proximate to the supersonic nozzle <NUM> by at least one screw or other mechanically suitable fastener.

Some implementations of the gas recovery nozzle <NUM> further comprise a flexible coupling <NUM> attached to the first end <NUM> and configured to engage the part <NUM>. The part <NUM> is any item (e.g., portion of an aircraft or helicopter) requiring CSAM repair processes. In some implementations, the flexible coupling <NUM> is ring-shaped and positioned proximate to the substrate of the part <NUM> and forms at least a partial seal between the gas recovery nozzle <NUM> and the part <NUM>. When forming at least a partial seal, the flexible coupling <NUM> comprises a gas capture cover <NUM>. The flexible coupling <NUM> is constructed of at least one of an elastomer, flexible metallic material, or other mechanically suitable material that is sufficiently durable to provide an acceptable service lifetime before needing replacement, and also able to conform to the contours and dimensions of variously shaped parts <NUM>. The flexible coupling <NUM>, which is configured as a gas capture cover <NUM> in the illustrated implementation, addresses the standout distance effect, which has considerable performance implications for any implementation of CSAM in general and the gas recovery nozzle <NUM> in particular. If the standout distance between the gas recovery nozzle <NUM> and the part <NUM> is too small, the gas recovery nozzle <NUM> will be subject to clogging and other phenomenon having a deleterious performance impact and eventually requiring cleaning or even replacement. If the standout distance between the gas recovery nozzle <NUM> and the part <NUM> is too great, the performance of the gas recovery nozzle <NUM> degrades, leading to the escape of some or even all of the gas <NUM> otherwise subject to capture by the gas recovery nozzle <NUM>. The flexible coupling <NUM> addresses the standout distance effect by (<NUM>) providing superior control of the exact standout distance during any CSAM repair session versus implementations not using the flexible coupling <NUM>, and (<NUM>) in some implementations, directly contacting or almost contacting the substrate of the part <NUM> to further reduce the amount of used gas able to escape recapture. In some implementations, the flexible coupling <NUM> further comprises a spring or mechanical or electrical actuator to maintain such contact or partial contact. In some implementations, the flexible coupling <NUM> is a single component; in other implementations the flexible coupling <NUM> is a mechanism with more than one component. Multi-part flexible couplings <NUM> include but are not limited to flexible couplings <NUM> assembled using petal joins.

Modelling and experiments using implementations of the present disclosure indicate that negligible or zero gas recovery occurs when the standout distance is greater than or equal to one millimeter. Various such models and experiments using standout distances less than one millimeter demonstrate recovery of at least fifty percent to at least ninety percent of the gas <NUM> used in a particular CSAM session incorporating the gas recovery nozzle <NUM> fitted with the flexible coupling <NUM>, depending on the standout distance. These models and experiments further indicate that implementations using a standout distance of <NUM> millimeters perform well, and the performance of implementations using <NUM> or less millimeters is optimal. <FIG> illustrates the gas recovery nozzle <NUM> comprising the flexible coupling <NUM> configured to mitigate the standout distance effect described above. By contrast, <FIG> as discussed elsewhere herein illustrates an implementation of a gas recovery nozzle not including the flexible coupling <NUM>, demonstrating that implementations of the disclosure are still functional even when a flexible coupling or gas capture cover is not present to mitigate the standout distance effect.

Some implementations of the gas recovery nozzle <NUM> further comprise a heat transfer device <NUM> proximate to the supersonic nozzle <NUM> and the main body <NUM>. The heat transfer device <NUM> is configured to regulate a temperature of the gas <NUM> such that the gas recovery nozzle <NUM> is protected from heat-induced damage from a flow of the gas <NUM>. In some such implementations, the heat transfer device <NUM> further comprises a liquid cooling system. The heat transfer device <NUM> is any suitable device for transferring waste heat. Depending on the requirements of a particular application of an implementation of the gas recovery nozzle <NUM>, the heat transfer device <NUM> is at least one of a heat pipe, heat sink, liquid cooling tube, or any other suitable heat transfer device or mechanism that is capable of transferring waste heat away from the gas <NUM> and or the gas recovery nozzle <NUM>. The gas expansion will reduce the temperature of the gas proximate to the first end <NUM>, cooling is more relevant close to the second end <NUM>.

In some implementations, the heat transfer device <NUM> is an open system, such as a liquid cooling tube wherein the fluid flowing through the liquid cooling tube is in thermal communication with one or more additional heat transfer devices, such as a heat sink such that heat may be transferred from the heat transfer device <NUM> to the heat sink. For instance, the heat sink can be cooled with air, liquid, or a fan, or the heat sink can be a cold plate, or any other suitable heat sink. In some other implementations, waste heat carried by the heat transfer device <NUM> is dissipated into space using protrusions in thermal communication with the heat transfer device <NUM>.

In some other implementations, the heat transfer device <NUM> is a closed system (e.g., a pulsating heat pipe ("PHP") or loop heat pipe ("LHP")). Each of the PHP and LHP are passive devices that operate under pressure differences caused by heat to force heated fluid to propagate toward a heat sink or other location where waste heat is withdrawn from the fluid. In yet other implementations, the heat transfer device <NUM> utilizes various configurations of heat pipes, such as straight, curved, crossing, or any number of configurations for achieving a desired amount of cooling. The heat transfer device <NUM> is configuration in various implementations to surround at least a portion of the main body <NUM> and be positioned between the main body <NUM> and the supersonic nozzle <NUM>.

<FIG> is a side elevation illustration of a spray path of an implementation of a cold spray additive manufacturing system <NUM> in use in accordance with an implementation. The cold spray additive manufacturing system <NUM> does not show a gas recovery nozzle (e.g., the gas recovery nozzle <NUM> of <FIG>), but instead illustrates how gas <NUM> (e.g., the gas <NUM> of <FIG>) is lost when the gas recovery nozzle is not present. A nozzle <NUM> (e.g., the supersonic nozzle <NUM> of <FIG>) propels additive particles <NUM> along the additive vector <NUM> to a substrate <NUM> through the nozzle <NUM> at a supersonic speed using the gas <NUM> to perform cold spray additive manufacturing of a part <NUM>. While the additive particles <NUM> bond to the part <NUM> as described in <FIG> herein, the used gas escapes laterally along the substrate of the part <NUM>, on the escape vector <NUM>. Without use of the gas recovery nozzle as disclosed elsewhere herein, all of the gas <NUM> is lost along the escape vector <NUM> and cannot be reused. In some implementations, there are multiple escape vectors <NUM>, each with a different direction. Gas traversing along any of the escape vectors <NUM> is permanently lost.

<FIG> is a flowchart illustrating a method <NUM> for performing cold spray additive manufacturing of a part (e.g., the part <NUM>) in accordance with an implementation. In some implementations, the process shown in <FIG> is performed by, at least in part, a gas recovery nozzle, a supersonic nozzle, a heat transfer device, and a gas recovery sub-system, such as the gas recovery nozzle <NUM>, the supersonic nozzle <NUM>, the heat transfer device <NUM>, and the gas recovery sub-system <NUM> in <FIG>. The method <NUM> propels particles to a substrate through a nozzle at a supersonic speed using a gas to perform cold spray additive manufacturing of a part at operation <NUM>, captures a flow of the gas propelled from an end of the nozzle at operation <NUM>, and circulates the flow of the gas to a gas recovery system at operation <NUM>. The method <NUM> allows for in-situ cold spray additive manufacturing of a part. In some implementations, the substrate comprises at least one of the original substrate of a part or material (e.g., particles) applied previously to the original substrate (e.g., via a previous application of a CSAM method).

Thereafter, the process is complete. While the operations illustrated in <FIG> are performed by, at least in part, a gas recovery nozzle, a supersonic nozzle, a heat transfer device, and a gas recovery sub-system, aspects of the disclosure contemplate performance of the operations by other entities. In some implementations, a cloud service performs one or more of the operations (e.g., by controlling the nozzle to cause particles to be propelled to a substrate through a nozzle at a supersonic speed using a gas to perform cold spray additive manufacturing of a part). In some implementations of the method <NUM>, the propelling of particles comprises structurally repairing the part in situ as further described elsewhere in this disclosure. In some other implementations, the gas comprises an at least one of a high-pressure Helium or Nitrogen gas. In yet other implementations, the gas comprises an at least one of a low-pressure Helium or Nitrogen gas.

<FIG> is a flow chart illustrating another method <NUM> for performing cold spray additive manufacturing of a part (e.g., the part <NUM>) in accordance with an implementation. In some implementations, the method shown in <FIG> is performed by, at least in part, a gas recovery nozzle, a supersonic nozzle, a heat transfer device, a gas recovery sub-system, a flexible coupling, and a gas capture cover, such as the gas recovery nozzle <NUM>, the supersonic nozzle <NUM>, the heat transfer device <NUM>, the gas recovery sub-system <NUM>, the flexible coupling <NUM>, and the gas capture cover <NUM> in <FIG>. The method <NUM> uses a flexible coupling attached to an end of the nozzle to seal a gas capture cover, coupled to the nozzle, to the part at operation <NUM>. Operations <NUM>, <NUM>, and <NUM> are similar to operations <NUM>, <NUM>, and <NUM> of the method <NUM> depicted in <FIG>, and accordingly the description will not be repeated. The method <NUM> accommodates for variations in standout distances as described in more detail herein.

Thereafter, the process is complete. While the operations illustrated in <FIG> are performed by performed by, at least in part, a gas recovery nozzle, a supersonic nozzle, a heat transfer device, a gas recovery sub-system, a flexible coupling, and a gas capture cover, aspects of the disclosure contemplate performance of the operations by other entities. In some implementations, a cloud service performs one or more of the operations (e.g., by controlling the nozzle to cause particles to be propelled to a substrate through a nozzle at a supersonic speed using a gas to perform cold spray additive manufacturing of a part).

An operating environment is illustrated in <FIG> showing a block diagram of an implementation of a system <NUM> for performing cold spray additive manufacturing with gas recovery in accordance with an implementation. The system <NUM> comprises a robotic control system <NUM> configured to control a cold spray apparatus <NUM>. In some implementations, the robotic control system further comprises a robotic positioning arm <NUM> (e.g., robotically controlled mechanical arm). In some implementations, the robotic control system <NUM> is a manual or at least partially automated apparatus. In some such implementations, the robotic control system is controllable using a computing device, such as the computing device <NUM> of <FIG> herein. In some implementations, the robotic positioning arm <NUM> is at least a five-axis positioning system that includes two axes for positioning in a plane of the part under repair, one axis for the standout distance, and two additional axes for additional requisite positioning. Alternatively, the robotic positioning arm <NUM> is at least a two axis positioning system for XY positioning in the plane of part under repair and a rolling system that maintains parallelism and standout distance with the substrate of the part under repair. The robotic positioning arm <NUM>, in some implementations, is an ADEPT® Viper robot from Omron Adept Technologies, Inc.

The cold spray apparatus <NUM> of the system <NUM> further comprises a supersonic nozzle <NUM> (e.g., implemented as the supersonic nozzle <NUM> of <FIG>) and is configured to perform cold spray additive manufacturing of a part <NUM> (e.g., the part <NUM> of <FIG>). In some implementations, the cold spray apparatus <NUM> is further configured to cold spray a powder <NUM> onto a substrate <NUM> of the part <NUM>. In such implementations, the cold spray apparatus <NUM> further comprises a source <NUM> of gas <NUM> connected to a gas control module <NUM>. The gas control module <NUM> controls the flow of the gas <NUM> through a first line <NUM> connected to the supersonic nozzle <NUM> and through a second line <NUM> connected to a powder chamber <NUM> and then to the supersonic nozzle <NUM>. The cold spray apparatus <NUM> additionally comprises a heater <NUM> that heats the gas <NUM> to a requisite temperature prior to entrance of the gas <NUM> into the supersonic nozzle <NUM>. In some implementations, the substrate <NUM> is also heated to further facilitate mechanical bonding.

In operation, the gas <NUM> flows through the first line <NUM> and the second line <NUM> causing the powder <NUM> located within the powder chamber <NUM> to be sprayed in a supersonic gas jet from the supersonic nozzle <NUM> as a particle stream <NUM>. The particle stream <NUM> is sprayed at a temperature below the melting point of the powder <NUM> and travels at a supersonic velocity from the supersonic nozzle <NUM>. In some implementations, the particle stream <NUM> travels at several times the speed of sound. (The exact speed of sound at a given time varies depending on local conditions). In some implementations, the particle stream <NUM> travels at least two- to four-times the speed of sound. The particle stream is deposited on the substrate <NUM> of the part <NUM>, whereby on impact on the substrate <NUM>, particles of the particle stream <NUM> undergo plastic deformation due to the supersonic velocity of the particle stream <NUM> and bond to each other and the substrate <NUM> of the part <NUM> using mechanical energy. The heater <NUM> accelerates the speed of the particle stream <NUM>, but the heat from the heated gas <NUM> is not transferred to the bonding of the particles of the particle stream <NUM>. Thus, the heat cannot cause deformities, warping, stresses, or other deleterious impacts to the bonding. In some implementations, once the cold spray process is complete the substrate <NUM> is further processes, such as polished to create or restore a smooth finish.

The system <NUM> further comprises a gas recovery nozzle <NUM> (e.g., implemented as the gas recovery nozzle <NUM> of <FIG>). The gas recovery nozzle <NUM> comprises a main body (e.g., implemented as the main body <NUM> of <FIG>) configured to attach to the supersonic nozzle; a first end (e.g., implemented as the first end <NUM> of <FIG>) having angled walls (e.g., implemented as the angled walls <NUM> of <FIG>) at an opening (e.g., implemented as the opening <NUM> of <FIG>) defining a gas flow path (e.g., implemented as the gas flow path <NUM> of <FIG>) from the supersonic nozzle and a passage (e.g., implemented as the passage <NUM> of <FIG>) extending from the first end to a second end (e.g., implemented as the second end <NUM> of <FIG>), the first end being a distal end and the second end being a proximal end relative to the supersonic nozzle.

The gas recovery nozzle <NUM> further comprises a cavity (e.g., implemented as the cavity <NUM> of <FIG>) surrounding the passage and configured to collect at least some gas <NUM> (e.g., such as the gas <NUM> of <FIG>) expelled from the supersonic nozzle and defining a gas recovery path (e.g., implemented as the gas recovery path <NUM> of <FIG>), and an outlet (e.g., implemented as the outlet <NUM> of <FIG>) within the main body configured to connect to a gas recovery sub-system <NUM> (e.g., implemented the gas recovery sub-system <NUM> of <FIG>). The gas recovery sub-system <NUM> is configured to connect to the outlet and also configured to collect at least some gas <NUM> expelled from the supersonic nozzle <NUM> through the gas recovery path into a storage device <NUM> (e.g., implemented as the moveable gas recovery tank <NUM> of <FIG>). The gas <NUM> is thereby collected into the storage device <NUM> and is stored for treatment and reuse in the cold spray apparatus <NUM>.

In some implementations, the gas recovery sub-system <NUM> further comprises a gas condenser <NUM> configured to condense at least some gas <NUM> in the storage device <NUM>, such that storage device <NUM> stores the greatest possible volume of at least some gas <NUM>. In some implementations, the gas condenser <NUM> is the compressor pump <NUM> of <FIG> or an equivalent device. The storage device <NUM> is configured to be transportable to a purifier configured to remove all contaminants from at least some gas <NUM> such that at least some gas <NUM> is suitable for re-use in the cold spray apparatus <NUM>.

In general, there are two types of cold spray repair techniques. Non-Structural Cold Spray is concerned with adding thickness to a part. This technology has been developed and matured to the point that the United States Department of Defense has installed Non-Structural Cold Spray repair systems at many depots. Non-structural cold spray does not require the use of Helium carrier gas, due to less demanding mechanical requirements. Various implementations of the disclosure herein are targeted to Structural Cold Spray, which is concerned not merely with adding thickness to existing parts but reconditioning and repair of damaged, worn, or otherwise out of spec parts. Among other applications, Structural Cold Spray is suitable to repair corrosion, repair cracks, or restore tolerances/exact dimensions. Additionally, some implementations of Structural Cold Spray do not require stripping and reapply the finish of the part subject to repair. As disclosed herein, CSAM mechanically bonds particles to a substrate using purely mechanical energy, with no need for added adhesives.

The implementations herein provide apparatuses, methods, and systems for using cold spray technology to conduct structural repairs in situ by capturing the flow of gas from the supersonic nozzle during a cold spray process and circulating the gas to a gas recovery sub-system for later reuse in additional cold spray processes. Some implementations of the gas recovery nozzle incorporate a cover (e.g., a flexible coupling) to capture the flow of gas and circulate the gas to the gas recovery sub-system. The disclosure herein operates at the point of repair to capture spent gas proximate to a supersonic nozzle via a gas recovery nozzle and store the gas for later purification and reuse.

Unless otherwise stated, any implementation described herein as being incorporated into or being used in combination with a specific type of vehicle (e.g., an aircraft or helicopter) shall be understood to be installable into and usable with any other type of vehicle (e.g., trains, submersibles, tanks, armored personnel carriers, watercraft, etc.). Implementations of the disclosure herein are well-suited to repairing aircraft in-situ as described elsewhere herein, allowing the service life of such aircraft to be maximally extended at lesser cost. Cold spray is recognized by various organizations as a solution distinct from and advantageous over thermal spray.

In particular, as aircraft enter the extreme ends of repeatedly extended service lifetimes, inevitably fleet fatigue causes cracks and other damage requiring structural repairs, part replacement, and part repair to keep the aircraft in service. This escalates the cost of keeping such aircraft flying due to requiring recurrent inspections to maintain air worthiness, eventual retrofits, and long lead times and high expenses associated with supply chain issues. Cold spray is especially well suited to perform these types of repairs in situ to rehabilitate existing parts of such aircraft (e.g., repairs performed on aircraft components in an aircraft hangar without disassembly), potentially significantly reducing maintenance costs and also lowing downtime for military aircraft platforms. In <NUM> (with revisions following in <NUM> and <NUM>), the United States Department of Defense adopted and promulgated MIL Spec MIL-STD-<NUM> ("DOD Manufacturing Process Standard, Materials Deposition, Cold Spray"). The MIL-STD-<NUM> standard has been adopted by various other organizations around the world.

The disclosure herein is usable in a number of present military and commercial cold spray applications. Such applications include but are not limited to:.

At the time of this disclosure, in cold spray applications using Helium without any means to recover and reuse the gas, the cost of each cold spray additive manufacturing repair session can include at least $<NUM>,<NUM>-$<NUM>,<NUM> per hour in unrecoverable, single-use Helium expenditures. In many instances, this comprises the majority of the expense for such cold spray additive manufacturing repair sessions. Such sessions take more time and cost more money the more complex the part is that is under repair. Without a means to reuse the Helium, the commercial economic viability of CSAM repair is severely curtailed.

Various implementations herein use a gas recovery sub-system (e.g., the gas recovery sub-system <NUM> of <FIG> or <NUM> of <FIG>) to gather and store used gas for later purification and reuse in future cold spray additive manufacturing processes. The disclosure is usable with a number of commercially available purification/purifier systems, including those both presently available and not yet released. In some implementations, the disclosure is usable with QUANTUMPURE CS™ and QuantumPure CS-TRI GAS™ Helium recovery and purification systems by Quantum Technology Corporation.

At least a portion of the functionality of the various elements in the figures are in some implementations performed by other elements in the figures, and or an entity (e.g., a computer) not shown in the figures.

In some implementations, the operations illustrated in <FIG> and <FIG> are performed by a single person, a group of persons, a fully- or partially-automated cold spray additive manufacturing with gas recovery system, or any combination of the foregoing. As an illustration, in some implementations the gas recovery nozzle, supersonic nozzle, heat transfer device, and gas recovery sub-system are each be provided by distinct suppliers to a wholly separate assembler who couples the gas recovery nozzle to the supersonic nozzle.

While the aspects of the disclosure have been described in terms of various implementations with their associated operations, a person skilled in the art would appreciate that a combination of operations from any number of different implementations is also within scope of the aspects of the disclosure.

The present disclosure is operable within an aircraft manufacturing and service method according to an implementation as a method <NUM> in <FIG>. During pre-production of the aircraft, some implementations of method <NUM> include specification and design of the aircraft at operation <NUM>, and material procurement at operation <NUM>. During production, some implementations of method <NUM> include component and subassembly manufacturing at operation <NUM> and aircraft system integration at operation <NUM>. The aircraft undergoes certification and delivery at operation <NUM> in order to be placed in service at operation <NUM>. While in service of a customer, the aircraft is scheduled for routine maintenance and service at operation <NUM>. In some implementations, operation <NUM> comprises modification, reconfiguration, refurbishment, and other operations associated with maintaining the aircraft in acceptable, safe condition during ongoing flight operations. Systems and methods for cold spray additive manufacturing as disclosed herein are used during operation <NUM>.

Each of the processes of method <NUM> are performable or practicable by a system integrator, a third party, or an operator (e.g., a customer). For the purposes of this disclosure, a system integrator comprises any number of aircraft manufacturers and major-system subcontractors; a third party comprises any number of vendors, subcontractors, and suppliers; and an operator comprises an airline, leasing company, military entity, service organization, and similar entities providing similar sales and leasing services.

The present disclosure is operable in a variety of terrestrial and extra-terrestrial environments for a variety of applications. For illustrative purposes only, and with no intent to limit the possible operating environments in which implementations of the disclosure operate, the following exemplary operating environment is presented. The present disclosure is operable within an aircraft operating environment according to an implementation as an aircraft <NUM> in <FIG>. Implementations of the aircraft <NUM> include but are not limited to an airframe <NUM>, a plurality of high-level systems <NUM>, and an interior <NUM>. Some implementations of the aircraft <NUM> incorporate high-level systems <NUM> including but not limited to: one or more of a propulsion system <NUM>, an electrical system <NUM>, a hydraulic system <NUM>, and an environmental system <NUM>. Any number of other systems may be included in implementations of the aircraft <NUM>. Although an aerospace implementation is shown, the principles are applicable to other industries, such as the automotive and nautical industries.

The present disclosure is operable with a computing apparatus according to an implementation as a functional block diagram <NUM> in <FIG>. In such an implementation, components of a computing apparatus <NUM> may be implemented as a part of an electronic device according to one or more implementations described in this specification. The computing apparatus <NUM> comprises one or more processors <NUM> which may be microprocessors, controllers or any other suitable type of processors for processing computer executable instructions to control the operation of the electronic device. Platform software comprising an operating system <NUM> or any other suitable platform software may be provided on the apparatus <NUM> to enable application software <NUM> to be executed on the device. According to an implementation, the cold spray additive manufacturing system as described herein may be implemented at least partially by software.

Computer executable instructions may be provided using any computer-readable media that are accessible by the computing apparatus <NUM>. Computer-readable media may include, without limitation, computer storage media such as a memory <NUM> and communications media. Computer storage media, such as a memory <NUM>, include volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or the like. Computer storage media include, but are not limited to, RAM, ROM, EPROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other non-transmission medium that is usable to store information for access by a computing apparatus. In contrast, communication media may embody computer readable instructions, data structures, program modules, or the like in a modulated data signal, such as a carrier wave, or other transport mechanism. As defined herein, computer storage media do not include communication media. Therefore, a computer storage medium should not be interpreted to be a propagating signal per se. Propagated signals per se are not examples of computer storage media. Although the computer storage medium (the memory <NUM>) is shown within the computing apparatus <NUM>, it will be appreciated by a person skilled in the art, that the storage may be distributed or located remotely and accessed via a network or other communication link (e.g., using a communication interface <NUM>).

The computing apparatus <NUM> may comprise an input/output controller <NUM> configured to output information to one or more output devices <NUM>, in some implementations a display or a speaker, which may be separate from or integral to the electronic device. The input/output controller <NUM> may also be configured to receive and process an input from one or more input devices <NUM>, in some implementations a keyboard, a microphone or a touchpad. In one implementation, the output device <NUM> may also act as the input device. A touch sensitive display is one such device. The input/output controller <NUM> may also output data to devices other than the output device, e.g., a locally connected printing device. In some implementations, a user may provide input to the input device(s) <NUM> and/or receive output from the output device(s) <NUM>.

The functionality described herein is performable, at least in part, by one or more hardware logic components. According to an implementation, the computing apparatus <NUM> is configured by the program code when executed by the processor <NUM> to execute the implementations of the operations and functionality described. Alternatively, or in addition, the functionality described herein is performable, at least in part, by one or more hardware logic components. Without limitation, illustrative types of hardware logic components that are usable include Field-programmable Gate Arrays (FPGAs), Application-specific Integrated Circuits (ASICs), Program-specific Standard Products (ASSPs), System-on-a-chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), Graphics Processing Units (GPUs).

Thus, various implementations include systems and methods for performing cold spray additive manufacturing with gas recovery comprising propelling particles to a substrate through a nozzle at a supersonic speed using a gas to perform cold spray additive manufacturing of a part; capturing a flow of the gas propelled from an end of the nozzle; and circulating the flow of the gas to a gas recovery system.

As described herein, the present disclosure provides systems and methods for cold spray additive manufacturing with gas recovery. The systems and methods herein efficiently and effectively construct and deploy within cold spray additive manufacturing with gas recovery system suitable for use in connection with repairs in situ of a number of moving vehicles, including but not limited to the above exemplary operating environment.

While various spatial and directional terms, such as top, bottom, lower, mid, lateral, horizontal, vertical, front and the like may be used to describe the present disclosure, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.

Any range or value given herein is extendable or alterable without losing the effect sought, as will be apparent to the skilled person.

Rather, the specific features and acts described above are disclosed as exemplary forms of implementing the claims.

It will be understood that the benefits and advantages described above can relate to one implementation or can relate to several implementations. The implementations are not limited to those that address every issue discussed in the Background herein or those that have any or all of the stated benefits and advantages.

The implementations illustrated and described herein as well as implementations not specifically described herein but within the scope of aspects of the claims constitute exemplary means for cold spray additive manufacturing with gas recovery.

The order of execution or performance of the operations in implementations of the disclosure illustrated and described herein is not essential, unless otherwise specified. As an illustration, it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of aspects of the disclosure.

When introducing elements of aspects of the disclosure or the implementations thereof, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements.

It is to be understood that the above description is intended to be illustrative, and not restrictive. As an illustration, the above-described implementations (and/or aspects thereof) are usable in combination with each other. In addition, many modifications are practicable to adapt a particular situation or material to the teachings of the various implementations of the disclosure without departing from the scope of the claims. While the dimensions and types of materials described herein are intended to define the parameters of the various implementations of the disclosure, the implementations are by no means limiting and are exemplary implementations. Many other implementations will be apparent to those of ordinary skill in the art upon reviewing the above description. The scope of the various implementations of the disclosure should, therefore, be determined with reference to the appended claims. In the appended claims, the terms "including" and "in which" are used as the plain-English equivalents of the respective terms "comprising" and "wherein. " Moreover, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on <NUM> U. § <NUM>(f), unless and until such claim limitations expressly use the phrase "means for" followed by a statement of function void of further structure.

This written description uses examples to disclose the various implementations of the disclosure, including the best mode, and also to enable any person of ordinary skill in the art to practice the various implementations of the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the various implementations of the disclosure is defined by the claims, and includes other examples that occur to those persons of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if the examples have structural elements that do not differ from the literal language of the claims. Further, there is disclosed a gas recovery nozzle comprising:.

Preferably, the outlet comprises an opening configured to connect to a compressor pump of the gas recovery sub-system; and.

Preferably, the outlet comprises an opening configured to connect to a movable gas recovery tank.

Preferably, the gas comprises an at least one of Helium or Nitrogen gas.

Preferably, the main body is tubular and configured to surround an end of the supersonic nozzle.

Preferably, the main body is configured as a removable cover to capture a flow of gas from the supersonic nozzle and circulate the gas to the gas recovery sub-system.

Preferably, the main body is configured as a removable cover to suppress noise during a cold spray process wherein gas is expelled from the supersonic nozzle.

Preferably, an open end of the cavity at a part side comprises curved walls.

Preferably, the open end of the cavity extends farther distally than the opening at the first end.

Preferably, the gas recovery nozzle further comprises a flexible coupling attached to the first end and configured to engage a part.

Preferably, the gas recovery nozzle further comprises a heat transfer device proximate to the supersonic nozzle and the main body, the heat transfer device configured to regulate a temperature of the gas such that the recovery nozzle is protected from heat-induced damage from a flow of the gas.

Preferably, the heat transfer device further comprises a liquid cooling system.

Still further, there is disclosed amethod for performing cold spray additive manufacturing, the method comprising:.

Preferably, the propelling of particles comprises structurally repairing the part in situ.

Preferably, the gas comprises an at least one a of a high-pressure Helium or Nitrogen gas.

Preferably, the method further comprises using a flexible coupling attached to an end of the nozzle to seal a gas capture cover, coupled to the nozzle, to the part.

Also, there is disclosed a system for performing cold spray additive manufacturing with gas recovery, comprising:.

Preferably, the robotic control system further comprises a robotic positioning arm.

Preferably, the cold spray apparatus is further configured to cold spray a powder onto a substrate of a part, the cold spray apparatus further comprising:.

Claim 1:
A gas recovery nozzle (<NUM>) for performing cold spray additive manufacturing of a part (<NUM>), comprising:
a main body (<NUM>) configured to attach to a supersonic nozzle (<NUM>), wherein portion of the main body (<NUM>) forms a passage (<NUM>) configured to surroundingly contact the supersonic nozzle (<NUM>), when the supersonic nozzle (<NUM>) is attached, inside a cavity (<NUM>) defined by the main body (<NUM>);
a first end (<NUM>) of the passage (<NUM>) having angled walls (<NUM>) at an opening (<NUM>) defining a gas flow path (<NUM>) from the supersonic nozzle (<NUM>) towards the part (<NUM>);
the passage (<NUM>) extending from the first end (<NUM>) to a second end (<NUM>), the first end (<NUM>) being a distal end and the second end (<NUM>) being a proximal end relative to the supersonic nozzle (<NUM>);
the cavity (<NUM>) surrounding the passage (<NUM>) and configured to collect at least some gas (<NUM>) which is expelled from the supersonic nozzle (<NUM>) and escapes laterally along a substrate of the part (<NUM>), and defining a gas recovery path (<NUM>), wherein the cavity (<NUM>) has an open end (<NUM>) facing the part (<NUM>); and
an outlet (<NUM>), provided in addition to the open end (<NUM>), within the main body (<NUM>) configured to connect to a gas recovery sub-system (<NUM>).