# US 10,865,482 B2 · Feedstock and methods of making feedstock for cold spray techniques

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- Number: US 10,865,482 B2
- Document ID: US10865482B2
- Status: Granted
- Kind: B2
- Application number: 15/824,726
- Filed: 2017-11-28
- Published: 2018-03-22
- Granted: 2020-12-15
- Earliest claimed: 2015-09-30
- Assignees: Delavan Inc.
- Applicants: Delavan, Inc.
- Inventors: Sergey Mironets; Thomas J. Martin; Aaron T. Nardi; Alexander Staroselsky
- Web page: https://patentgrep.com/patent/US10865482B2

## CPC

- C23C 24/04: Impact or kinetic deposition of particles
- C09D 7/69: {Particle size larger than 1000 nm}
- C09D 7/70: {characterised by shape, e.g. fibres, flakes or microspheres}
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)

## Abstract

A feedstock for a cold spray process includes a plurality of globule bodies. The globule bodies include a plurality of discrete particles bonded to one another to define porous globule bodies. The bonds between the particles are of sufficient strength such that the globule bodies can retain both the body integrity as well as the body shape when the body experiences acceleration from a conveying gas in a cold spray technique. Methods of making the feedstock and globule bodies are also described.

## Claims

### Claim 1

A method making feedstock for a cold spray process, the method comprising:
receiving particulate;
agglomerating the particulate into a plurality globules;
strengthening the globules using heat, wherein strengthening imparts to the globules strength sufficient to retain both integrity and shape while undergoing acceleration in a cold spray process; and
shaping the globules, wherein the agglomerating the globules includes bonding particles of the particulate such that one or more pores are defined within the globules, wherein shaping the globule bodies include shaping the plurality of globule bodies such that the respective globule bodies are about twenty-five (25) millimeters in size.

### Claim 2 (depends on 1)

The method as recited in claim 1, wherein shaping the globules includes imparting a substantially spherical shape to one or more of the globules.

### Claim 3 (depends on 1)

The method as recited in claim 1, wherein shaping the globules includes imparting a non-spherical shape to one or more of the globules.

### Claim 4 (depends on 1)

The method as recited in claim 1, wherein agglomerating the particulate into a plurality of globules includes free-gravity sintering the agglomerated particulate in a mold.

### Claim 5 (depends on 1)

The method as recited in claim 1, wherein agglomerating the particulate into a plurality of globules includes heating free-gravity heating the agglomerated particulate at a temperature below a sintering temperature of the particulate.

### Claim 6 (depends on 1)

The method as recited in claim 1, wherein agglomerating the particulate and strengthening the agglomerated particulate is performed within an inert atmosphere.

### Claim 7 (depends on 1)

The method as recited in claim 1, wherein agglomerating the particulate includes agglomerating the particulate using a wet agglomeration technique.