US 12,233,456 B1
Method for cold spray additive manufacturing
Marius D. Ellingsen, Rapid City, SD (US); Aaron Nardi, East Granby, CT (US); and Isaac Nault, Bel Air, MD (US)
Filed by Marius D. Ellingsen, Rapid City, SD (US); Aaron Nardi, East Granby, CT (US); and Isaac Nault, Bel Air, MD (US)
Filed on Jun. 10, 2022, as Appl. No. 17/837,120.
Claims priority of provisional application 63/211,586, filed on Jun. 17, 2021.
Int. Cl. B22F 10/38 (2021.01); B22F 10/25 (2021.01); B22F 12/00 (2021.01); B22F 12/53 (2021.01); B33Y 10/00 (2015.01); B33Y 50/00 (2015.01); C23C 24/04 (2006.01)
CPC B22F 10/38 (2021.01) [B22F 10/25 (2021.01); B22F 12/224 (2021.01); B22F 12/53 (2021.01); B33Y 10/00 (2014.12); B33Y 50/00 (2014.12); C23C 24/04 (2013.01); B22F 2203/00 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method of additive manufacturing using a cold spray deposition apparatus having a nozzle from which particles of a cold spray material are sprayed, the nozzle having a central axis forming an impact angle with a supporting surface on which the material is to be deposited, the method comprising:
providing an additive material for application to the supporting surface using a cold spray deposition technique;
analyzing characteristics of deposited cold spray material, including:
forming a single line of deposited cold spray material on the supporting surface using the cold spray deposition technique by moving the nozzle of the cold spray deposition apparatus along the supporting surface and emanating particles of the cold spray material from the nozzle onto the supporting surface;
measuring at least one material property of the deposited cold spray material; and
generating a model of a geometric profile characteristic and a material defect characteristic of the single line of deposited cold spray material as a function of the impact angle of cold spray material sprayed from the cold spray deposition apparatus;
selecting a proposed path of movement of the nozzle of the cold spray deposition apparatus with respect to the supporting surface;
predicting, using the generated model, a bulk deposit geometry and a material defect distribution resulting from the proposed path of movement of the nozzle of the cold spray deposition apparatus;
modifying the proposed path of movement of the nozzle of the cold spray deposition apparatus to reduce error between the predicted bulk deposit geometry and a desired contour of the exterior of the component and reduce a defect distribution present in the component;
initiating spray deposition of the particles of the cold spray material from the nozzle of the cold spray deposition apparatus; and
moving the nozzle of the cold spray deposition apparatus along the modified path of movement of the nozzle.