US 11,980,944 B2
Systems, methods, and products for creating gas atomized metal matrix composite-based feedstock for cold spray background
Bruno Zamorano Senderos, Huntsville, AL (US); Ali Yousefiani, Huntington Beach, CA (US); Michael B. Nicholas, Mesa, AZ (US); and Rogie I. Rodriguez, Huntsville, AL (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Arlington, VA (US)
Filed on Apr. 7, 2023, as Appl. No. 18/297,271.
Application 18/297,271 is a division of application No. 16/698,730, filed on Nov. 27, 2019, granted, now 11,628,499.
Prior Publication US 2023/0241678 A1, Aug. 3, 2023
Int. Cl. B22F 9/08 (2006.01); C22C 1/051 (2023.01)
CPC B22F 9/082 (2013.01) [C22C 1/051 (2013.01); B22F 2302/05 (2013.01); B22F 2302/253 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A gas atomization system for producing a feedstock powder for cold spraying, comprising:
an intake sub-system configured to receive a metal matrix composite (MMC) material, the MMC material comprising metal particles and ceramic particles;
an atomizer sub-system configured to conduct gas atomization of the MMC material, the atomizer sub-system comprising:
a heating unit configured to heat the MMC material to a temperature for gas atomization;
a pressurization unit configured to apply a gas stream at a gas pressure for gas atomization;
a flow regulation unit configured to maintain a metal flow rate for gas atomization; and
the gas atomization comprising:
atomizing the MMC material at the gas pressure and the metal flow rate, while maintaining the temperature of the MMC material; and
producing the feedstock powder comprised of the metal particles that are embedded with the ceramic particles from the atomized MMC material.