# US 11,998,942 B2 · Cold spray device and system

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- Number: US 11,998,942 B2
- Document ID: US11998942B2
- Status: Granted
- Kind: B2
- Application number: 17/684,921
- Filed: 2022-03-02
- Published: 2022-06-16
- Granted: 2024-06-04
- Earliest claimed: 2012-10-29
- Assignees: South Dakota Board of Regents; Government of the United States of America, AS Represented By the Secretary of the Army
- Applicants: South Dakota Board of Regents
- Inventors: Christian Widener; Victor Champagne; Matthew Trexler; Dennis Helfritch; Rob Hrabe
- Web page: https://patentgrep.com/patent/US11998942B2

## CPC

- B05B 7/1693: {with means for heating the material to be sprayed or an atomizing fluid in a supply hose or the like}
- B05B 7/1486: {for spraying particulate material in dry state}
- B05B 7/1613: {comprising means for heating the atomising fluid before mixing with the material to be sprayed}
- C23C 24/04: Impact or kinetic deposition of particles
- B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D)
- 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)

## Abstract

Cold spray devices and systems are disclosed. They include a flowpath having an inlet adapted for receiving communication with two or more inputs and an outlet adapted to discharge the two or more inputs. A discharge nozzle may be included in the flowpath of the outlet and a confluence may be included in the flowpath at the inlet for combining the two or more inputs. A nozzle body houses the discharge nozzle separate and downstream from the confluence of the two inputs.

## Claims

### Claim 1

A cold spray device comprising:
a discharge system comprising:
a nozzle body for discharging a gas-powder mixture;
a gas-powder mixture input side on the nozzle body adapted for downstream communication with a gas-powder mixing manifold;
a gas-powder mixture output side on the nozzle body;
a flowpath system which communicates a powder and a heated gas to the mixing manifold; the flowpath system comprising:
a gas-powder flowpath in communication with the input side and output side of the nozzle body; and wherein the gas-powder mixture comprises a gas temperature and powder temperature, wherein the powder temperature is generally at the gas temperature at the input side; and
a control system operably configured to control the discharge system and the flowpath system and monitor inputs and responses to detected pressures and temperatures, the control system comprising:
at least one sensor housed within the nozzle body for measuring a pressure of the gas-powder mixture prior to and after being discharged from the output side of the nozzle body.

### Claim 2 (depends on 1)

The cold spray device of claim 1, further comprising:
a single gas-powder line housing the gas-powder flowpath within the flowpath system, the gas-powder line connected between the input side and output side of the nozzle body.

### Claim 3 (depends on 1)

The cold spray device of claim 1, further comprising:
a heaterless nozzle body.

### Claim 4 (depends on 1)

The cold spray device of claim 1, wherein the nozzle body comprises a single input for discharging the gas-powder mixture from the output side of the nozzle body.

### Claim 5 (depends on 1)

The cold spray device of claim 1, wherein the at least one sensor housed within the nozzle body is configured for measuring a temperature of the gas-powder mixture prior to and after being discharged from the output side of the nozzle body.

### Claim 6 (depends on 1)

The cold spray device of claim 1, wherein the nozzle body comprises a single input for receiving the gas-powder mixture.

### Claim 7 (depends on 6)

The cold spray device of claim 6, wherein the gas-powder mixing manifold comprises a single output for communicating the gas-powder mixture to the single input of the nozzle body.