# US 10,501,827 B2 · Method to join dissimilar materials by the cold spray process

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- Number: US 10,501,827 B2
- Document ID: US10501827B2
- Status: Granted
- Kind: B2
- Application number: 14/499,282
- Filed: 2014-09-29
- Published: 2016-03-31
- Granted: 2019-12-10
- Earliest claimed: 2014-09-29
- Assignees: The United Statesd of America as represented by the Secretary of the Army
- Applicants: U.S. Army Research Laboratory ATTN:RDRL-LOC-I
- Inventors: Victor K. Champagne, Jr.; Victor K. Champagne, III
- Web page: https://patentgrep.com/patent/US10501827B2

## CPC

- C22C 21/08: with silicon
- B23K 28/02: Combined welding or cutting procedures or apparatus
- B23K 35/36: Selection of non-metallic compositions, e.g. coatings or fluxes (B23K35/34 takes precedence); Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- C04B 37/026: {consisting of metals or metal salts}
- C22C 23/04: with zinc or cadmium as the next major constituent
- B23K 2103/02: Iron or ferrous alloys
- B23K 2103/10: Aluminium or alloys thereof
- B23K 2103/12: Copper or alloys thereof
- B23K 2103/14: Titanium or alloys thereof
- B23K 2103/15: {Magnesium or alloys thereof}
- B23K 2103/18: Dissimilar materials
- B23K 2103/20: Ferrous alloys and aluminium or alloys thereof
- B23K 2103/42: {Plastics other than composite materials}
- B23K 2103/52: {Ceramics}
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

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.

## Claims

### Claim 1

A process for joining dissimilar materials comprising:
providing a first component made from a first material and a second component made from a second material, the first material and the second material being dissimilar materials; wherein the first material is magnesium or a magnesium alloy and the second material is aluminum or an aluminum alloy;
degassing the particles of the second material under high vacuum conditions of from 10−4 to 10−6 torr and heating the particles of the second material between 260 and 400° C.;
annealing particles of the second material in a reducing atmosphere prior to cold spraying the particles;
cold spraying the annealed particles of the second material to form a bead of the second material onto the first component wherein the bead has an adhesion strength to the first component and/or the second component that is greater than an ultimate tensile strength of the first component and/or the second component individually or in combination; and
joining the second component to the bead on the first component and forming a weldment of the first component and the second component at a temperature below the melting temperatures of both the first material and the second material.

### Claim 2 (depends on 1)

The process of claim 1, wherein the particles are aluminum or an aluminum alloy.

### Claim 3 (depends on 2)

The process of claim 2, wherein the particles are ellipsoid shaped.

### Claim 4 (depends on 1)

The process of claim 1, wherein joining the second component to the bead on the first component is by fusion welding the bead and the second component together.

### Claim 5 (depends on 4)

The process of claim 4, wherein the weldment is a butt joint between the first component and the second component.

### Claim 6 (depends on 4)

The process of claim 4, wherein the weldment is a lap joint between the first component and the second component.

### Claim 7 (depends on 1)

The process of claim 1, wherein joining the second component to the bead on the first component is by cold spraying another bead between the bead and the second component.

### Claim 8 (depends on 7)

The process of claim 7, wherein the weldment is a butt joint between the first component and the second component.

### Claim 9 (depends on 7)

The process of claim 7, wherein the weldment is a lap joint between the first component and the second component.

### Claim 10 (depends on 1)

The process of claim 1, wherein joining the second component to the bead on the first component further comprises brazing the bead and the second component together.

### Claim 11 (depends on 10)

The process of claim 10, wherein the weldment is a butt joint between the first component and the second component.

### Claim 12 (depends on 10)

The process of claim 10, wherein the weldment is a lap joint between the first component and the second component.

### Claim 13 (depends on 1)

The process of claim 1, wherein the bead between the first component and the second component is in a compressive stress state.

### Claim 14 (depends on 1)

The process of claim 1, wherein the cold spraying is performed using a hand held and hand maneuvered nozzle.

### Claim 15 (depends on 1)

The process of claim 1, wherein the cold spraying is performed using a robotic held and maneuvered nozzle.

### Claim 16 (depends on 1)

The process of claim 1, wherein an interface between the bead and the first component is void of a heat affected zone.

### Claim 17 (depends on 1)

The process of claim 1, wherein an interface between the bead and the first component is void of an intermetallic layer.