Abstract: Powder fluidizing apparatus includes a unitary pressure vessel having a powder compartment and a transfer compartment, a lid on a first open end of the powder compartment and a base on a second end of the unitary pressure vessel, the second end sealing an open end of the transfer compartment. A plate separates the powder compartment from the transfer compartment, the plate being located between the lid and the base. A coupling collar secures a sieve disk packet in an opening in the plate. A tube extends from the transfer compartment to the powder compartment, the tube extending to a location near the lid of the unitary pressure vessel. When the transfer compartment is pressurized with a carrier gas, pressure in the transfer compartment and pressure in the powder compartment are equalized by the tube.

Abstract: Powder fluidizing apparatus includes a unitary pressure vessel having a powder compartment and a transfer compartment, a lid on a first open end of the powder compartment and a base on a second end of the unitary pressure vessel, the second end sealing an open end of the transfer compartment. A plate separates the powder compartment from the transfer compartment, the plate being located between the lid and the base. A coupling collar secures a sieve disk packet in an opening in the plate. A tube extends from the transfer compartment to the powder compartment, the tube extending to a location near the lid of the unitary pressure vessel. When the transfer compartment is pressurized with a carrier gas, pressure in the transfer compartment and pressure in the powder compartment are equalized by the tube.

Abstract: A rotary coating tool includes a rotary tool for coating bores and surfaces using solid-state deposition and consolidation of high velocity powder particles undergoing thermal plastic deformation.

Abstract: Impact consolidated powders form deposits that are densified by substantially simultaneous shot peening of the impact consolidated powder.

Abstract: Impact consolidated powders form deposits that are densified by substantially simultaneous shot peening of the impact consolidated powder.

Abstract: A powder-fluidizing apparatus is presented which is applicable to feeding ultra-fine and nano-size powders, and powders with a broad particle size distribution, in a uniform manner over a long period of time. Generally, this is accomplished by using a rotating brush to sweep the powder through holes in a removable sieve plate, which breaks up agglomerated particles in the powder and controls the powder feed rate. The powder then drops from the holes into a funnel, where it is fluidized by being entrained into a carrier gas, and then flows through the funnel out of the apparatus to an applicator. The funnel surface is vibrated to avoid powder build-up on the surface that can break loose and cause pulses of increased material in the powder flow. Ultrasonic waves are introduced into the funnel to break up any agglomerated particles remaining in the powder before it reaches the applicator.

Abstract: A powder-fluidizing apparatus is presented which is applicable to feeding ultra-fine and nano-size powders, and powders with a broad particle size distribution, in a uniform manner over a long period of time. Generally, this is accomplished by using a rotating brush to sweep the powder through holes in a removable sieve plate, which breaks up agglomerated particles in the powder and controls the powder feed rate. The powder then drops from the holes into a funnel, where it is fluidized by being entrained into a carrier gas, and then flows through the funnel out of the apparatus to an applicator. The funnel surface is vibrated to avoid powder build-up on the surface that can break loose and cause pulses of increased material in the powder flow. Ultrasonic waves are introduced into the funnel to break up any agglomerated particles remaining in the powder before it reaches the applicator.

Abstract: The invention relates to an apparatus and process for solid-state deposition and consolidation of powder particles entrained in a subsonic or sonic gas jet onto the surface of an object. Under high velocity impact and thermal plastic deformation, the powder particles adhesively bond to the substrate and cohesively bond together to form consolidated materials with metallurgical bonds. The powder particles and optionally the surface of the object are heated to a temperature that reduces yield strength and permits plastic deformation at low flow stress levels during high velocity impact, but which is not so high as to melt the powder particles.

Abstract: The invention relates to various methods for modifying material properties during solid-state impact consolidation of coatings and free-form fabrication of structures. The invention discloses a new method for modifying the physical and chemical properties of the substrate, coating, and free-form structure during and simultaneous to impact consolidation and accretion of powders using a solid-state deposition process. The physical and chemical properties of the substrate, coating, and free-form structure in close proximity to the impact consolidation process can be modified by heating or by exposing to gaseous and liquid environments. Heating of the substrate, coating, or free-form structure up to annealing temperatures for most materials significantly reduces the plastic deformation flow stresses and permits the impact consolidation process to enhance deposition efficiency, improve densification, anneal dislocations, and improve adhesion and cohesion through in-situ diffusion bonding.

Abstract: The invention relates to an apparatus and process for solid-state deposition and consolidation of powder particles entrained in a subsonic or sonic gas jet onto the surface of an object. Under high velocity impact and thermal plastic deformation, the powder particles adhesively bond to the substrate and cohesively bond together to form consolidated materials with metallurgical bonds. The powder particles and optionally the surface of the object are heated to a temperature that reduces yield strength and permits plastic deformation at low flow stress levels during high velocity impact, but which is not so high as to melt the powder particles.

Abstract: The invention relates to an apparatus and process for solid-state deposition and consolidation of powder particles entrained in a subsonic or sonic gas jet onto the surface of an object. Under high velocity impact and thermal plastic deformation, the powder particles adhesively bond to the substrate and cohesively bond together to form consolidated materials with metallurgical bonds. The powder particles and optionally the surface of the object are heated to a temperature that reduces yield strength and permits plastic deformation at low flow stress levels during high velocity impact, but which is not so high as to melt the powder particles.

Abstract: The invention relates to a powder-fluidizing and feeding device for use with coating and spray forming nozzles and guns. The device includes novel provisions for controlling and feeding powder from a hopper to a vibrating bowl, for heating and vibrating powders in the hopper to dissipate agglomeration and clumping of the powder, and for metering powders from a vibrating bowl to the spray nozzles and guns using a feedback control derived from powder mass loss rate measurements. The device is particularly useful for feeding ultra-fine and nanoscale particles, which are difficult to feed uniformly with the prior art of conventional powder feeders.

Abstract: The invention relates to a powder-fluidizing and feeding device for use with coating and spray forming nozzles and guns. The device includes novel provisions for controlling and feeding powder from a hopper to a vibrating bowl, for heating and vibrating powders in the hopper to dissipate agglomeration and clumping of the powder, and for metering powders from a vibrating bowl to the spray nozzles and guns using a feedback control derived from powder mass loss rate measurements. The device is particularly useful for feeding ultra-fine and nanoscale particles, which are difficult to feed uniformly with the prior art of conventional powder feeders.

Abstract: The invention relates to an apparatus and process for solid-state deposition and consolidation of powder particles entrained in a subsonic or sonic gas jet onto the surface of an object. Under high velocity impact and thermal plastic deformation, the powder particles adhesively bond to the substrate and cohesively bond together to form consolidated materials with metallurgical bonds. The powder particles and optionally the surface of the object are heated to a temperature that reduces yield strength and permits plastic deformation at low flow stress levels during high velocity impact, but which is not so high as to melt the powder particles.

Abstract: An environmentally compliant triboelectric applicator and process for coating or ablating a substrate and for retrieving excess or ejected material from the substrate. The applicator comprises an inner supersonic nozzle for accelerating triboelectrically charged projectile particles entrained in a supersonic gas to speeds sufficiently high to coat or ablate a substrate. The applicator further comprises an outer evacuator nozzle coaxially surrounding the inner supersonic nozzle for retrieving excess projectile particles, ablated substrate powders, or other environmentally hazardous materials. A fluid dynamic coupling uses the efficacy of the Mach turning angle associated with a supersonic boundary layer of carrier gas to aspirate the central core of the supersonic two-phase jet.

Abstract: An environmentally compliant triboelectric applicator and process for coating or ablating a substrate and for retrieving excess or ejected material from the substrate. The applicator comprises an inner supersonic nozzle for accelerating triboelectrically charged projectile particles entrained in a supersonic gas to speeds sufficiently high to coat or ablate a substrate and an outer evacuator nozzle coaxially surrounding the inner supersonic nozzle for retrieving excess projectile particles, ablated substrate powders, or other environmentally hazardous materials. A fluid dynamic coupling uses the efficacy of the Mach turning angle associated with a supersonic boundary layer of carrier gas to aspirate the central core of the supersonic two-phase jet.