# US 9,433,957 B2 · Cold spray systems with in-situ powder manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,433,957 B2 - Document ID: US9433957B2 - Status: Granted - Kind: B2 - Application number: 14/591,091 - Filed: 2015-01-07 - Published: 2015-07-09 - Granted: 2016-09-06 - Earliest claimed: 2014-01-08 - Assignees: United Technologies Corporation - Applicants: United Technologies Corporation - Inventors: Aaron T. Nardi; Michael A. Klecka; Daniel V. Viens - Web page: https://patentgrep.com/patent/US9433957B2 ## CPC - B05B 7/1404: {Arrangements for supplying particulate material} - B22F 9/14: using electric discharge - C23C 24/04: Impact or kinetic deposition of particles - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - 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) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - 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 A cold spray system includes a powder generator and a powder feeder. The powder generator has a powder source disposed within a housing. The powder feeder is in fluid communication with the housing and the powder generator within the housing. A closed circuit defined from the powder generator to the powder feeder conveys powder from the powder generator to the powder feeder without exposing the powder to contaminates from outside the closed circuit. ## Claims ### Claim 1 A cold spray system, comprising: a powder generator having a powder source disposed within a housing; a powder feeder in fluid communication with the housing, wherein a closed circuit with an inert atmosphere is defined from the powder generator to the powder feeder for conveying powder from the powder generator to the powder feeder without exposing the powder to contaminates from outside the closed circuit; and a motive gas system in fluid communication with the powder generator for propelling particles produced in the powder generator through the closed circuit. ### Claim 2 (depends on 1) A system as recited in claim 1, wherein in the powder generator is housed within a generator chamber with an inert atmosphere. ### Claim 3 (depends on 1) A system as recited in claim 1, wherein the powder generator, powder feeder, and closed circuit are configured to supply particles having surface and interior portions with substantially the same composition. ### Claim 4 (depends on 1) A system as recited in claim 1, further comprising voltage source and return terminals operatively associated with the powder generator for developing an arc within the generator. ### Claim 5 (depends on 4) A system as recited in claim 4, further comprising first and second feedstock wires, bars, or rods connected to the voltage source and return terminals for generating an arc between the wires. ### Claim 6 (depends on 5) A system as recited in claim 5, wherein the first and second feedstock wires include aluminum or aluminum alloy. ### Claim 7 (depends on 6) A system as recited in claim 6, further comprising respective first and second wire feeders configured to feed the first and second wires within the chamber as the first and second wires are consumed to produce particles. ### Claim 8 (depends on 1) A system as recited in claim 1, wherein the motive gas system includes a supply of inert gas selected from the group consisting of argon, helium, and nitrogen. ### Claim 9 A cold spray system, comprising: a powder generator having a powder source disposed within a housing; a powder feeder in fluid communication with the housing, wherein a closed circuit with an inert atmosphere is defined from the powder generator to the powder feeder for conveying powder from the powder generator to the powder feeder without exposing the powder to contaminates from outside the closed circuit and a classifier in fluid communication with the powder generator, wherein the classifier is configured for removing particles outside of a predetermined size range from a particle flow through the closed circuit. ### Claim 10 (depends on 9) A system as recited in claim 9, wherein the classifier includes a vortex generator for separating particles by particle size. ### Claim 11 (depends on 10) A system as recited in claim 10, further including a quarantine module with an inert atmosphere in selective fluid communication with the classifier for capturing particles above a predetermined size separated by the classifier. ### Claim 12 (depends on 11) A system as recited in claim 11, wherein the quarantine module has an inert atmosphere for storing particles above a predetermined size separated by the classifier. ### Claim 13 A cold spray system, comprising: a powder generator having a powder source disposed within a housing; a powder feeder in fluid communication with the housing, wherein a closed circuit with an inert atmosphere is defined from the powder generator to the powder feeder for conveying powder from the powder generator to the powder feeder without exposing the powder to contaminates from outside the closed circuit; and a feedstock hopper in fluid communication with the powder generator and with the powder feeder for storing particles to regulate between a particle production rate of the powder generator and a particle usage rate of the powder feeder. ### Claim 14 (depends on 1) A system as recited in claim 1, further including an issue nozzle in fluid communication with the powder generator and configured for issuing a spray of powder at a substrate arranged opposite the nozzle. ### Claim 15 A cold spray system, comprising: a powder generator having a powder source disposed within a housing; a classifier for removing particles outside of a predetermined size range from a particle flow received from powder generator; a feedstock hopper for storing particles received from the classifier to regulate between a particle production rate of the powder generator and a particle usage rate of the powder feeder; and a powder feeder for feeding a consistent flow of particles received from the feedstock hopper, wherein a closed circuit with an inert atmosphere is defined from the powder generator to the powder feeder including the classifier and feedstock hopper for conveying powder from the powder generator to the powder feeder without exposing the powder to contaminates from outside the closed circuit. ### Claim 16 (depends on 15) A system as recited in claim 15, further including a quarantine module with an inert atmosphere in selective fluid communication with the classifier for capturing particles above a predetermined size separated by and received from the classifier. ### Claim 17 (depends on 16) A system as recited in claim 16, wherein the quarantine module has an inert atmosphere for storing particles above a predetermined size separated by the classifier. ### Claim 18 (depends on 16) A system as recited in claim 16, wherein the classifier has a first outlet in fluid communication with the feedstock hopper for discharging a flow of particles within the predetermined range, wherein the classifier has a second outlet in fluid communication with the quarantine module for discharging a flow of particles outside of the predetermined range. ### Claim 19 A method of cold spraying, comprising: generating powder within an inert environment of a powder generator chamber; removing particles of a predetermined size from the generated powder; conveying the generated powder having particles smaller than the predetermined size to a powder feeder in fluid communication with the power generator through a closed circuit without exposing the powder to contaminate from outside the closed circuit; and issuing a flow of particles as a spray from a nozzle in fluid communication with the powder feeder.