Abstract: A process of forming a MAXMET composite coating or component on an article, that in the case of components can be removed, comprising providing an article having a substrate. The process includes providing at least one powder containing the MAXMET composite, wherein the MAXMET composite comprises a mixture of MAX phase particles and metal. Cold spraying the at least one powder on the substrate at a critical velocity. Forming a layer of the MAXMET composite on the substrate.

Abstract: A method includes introducing metallic powder into a fluidizing chamber of a fluidized bed reactor. A fluidization gas is flowed into the fluidizing chamber. The metallic power becomes entrained in the flow of the fluidization gas. Adsorbed water is removed from the metallic powder by exposing the metallic powder to the fluidization gas for a duration of time and at a treatment temperature to cause the adsorbed water to be removed from the metallic powder.

Abstract: A component may be self-monitoring having a sensor assembly located on a surface of a substrate and covered by an encapsulating layer additively manufactured over the sensor assembly and thereby bonded to the substrate. The sensor may be wireless, self-powered, and embedded into the substrate such that it is unobtrusive and may not limit the performance or function of the component.

Abstract: A disclosed method of hard coating a wear surface of a valve of an aircraft air management system is performed by depositing a hardface alloy powder onto the wear surface, heating the wear surface and the hardface alloy powder to transform the hardface alloy powder into a molten liquid mass, and subsequently cooling the molten liquid hardface alloy mass to solidify the hardface alloy onto the wear surface. The disclosed process provides for localized application and subsequent bonding of the hardface alloy to discrete portions of the wear surface. The solidified hardface alloy coating may then be machined to obtain specific wear surface geometries.

Abstract: One embodiment includes a method for enhancing bond strength between a powder deposit and a substrate. Powder is deposited on the substrate. Powder is shot peened with peening media that is harder than both the powder and the substrate to produce bond strength between the powder and the substrate that is at least twice bond strength between the powder and the substrate without shot peening.

Abstract: A feedstock for a cold spray process includes a plurality of globule bodies. The globule bodies include a plurality of discrete particles bonded to one another to define porous globule bodies. The bonds between the particles are of sufficient strength such that the globule bodies can retain both the body integrity as well as the body shape when the body experiences acceleration from a conveying gas in a cold spray technique. Methods of making the feedstock and globule bodies are also described.

Abstract: A gas turbine engine includes an airfoil having a core that has a first hardness and a surface on the core. The surface includes a plurality of geometric features that have a second, greater hardness. The geometric features define a surface porosity by area percent and a corresponding surface solidity by area percent. The surface includes a ratio of the surface solidity divided by the surface porosity that is 1.8 or greater. The geometric features and the ratio establish the surface to be hydrophobic, and the second, greater hardness and the ratio establish an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions.

Abstract: A powder classification apparatus (10; 110; 210) includes a first chamber (12; 112; 212) that includes a fluidized bed and has an inlet (16; 116; 216A) and an outlet (18; 118; 218), the inlet (16; 116; 216A) configured to receive a gas (G) and distribute the gas (G) in a uniform flow through the first chamber (12; 112; 212), the first chamber (12; 112; 212) configured to receive a powder (P) and the gas (G) and create a fluidization zone, the outlet (18; 118; 218) configured to allow at least a portion of the powder (P) to exit the first chamber (12; 112; 212); and a second chamber (14; 114; 214) having a powder inlet (24; 124; 224) configured to accept at least a portion of the powder (P) from the outlet (18; 118; 218) in the first chamber (12; 112; 212) caused by at least a portion of the powder (P) being ejected from the first chamber (12; 112; 212) by the gas (G).

Abstract: The invention provides a self-peening feedstock material for cold spray deposition comprising a higher ductility matrix material and a hardened particle.

Abstract: A method of applying a metal comprising titanium to a substrate is disclosed. The method comprises nitriding the surface of metal powder particles comprising titanium by contacting the particles with a first gas comprising nitrogen in a fluidized bed reactor, and depositing the metal powder particles onto the substrate with cold spray deposition using a second gas.

Abstract: A powder feeder for a cold spray system includes a rotatable drum body, a housing surrounding the drum body, and a support structure. The support structure couples to the housing and supports the housing such that the drum body rotates about a rotation axis to provide in-situ blending of powder disposed within an interior of the drum body.

Abstract: A vibration damper for an additively manufactured structure includes a structure at least partially formed with an additive manufacturing technique. Also included is a damping element embedded within the structure at an internal location of the structure. A method of damping vibration of an additively manufactured component is provided. The method includes additively manufacturing a structure. The method also includes embedding at least one damping element within the structure at an internal location of the structure.

Abstract: A method of repairing or, in certain cases, strengthening a metallic substrate at a damage site is provided and includes removing material from the substrate around the damage site to form a recess, and cold spraying particulate material into the recess to form a bead of deposited material.

Abstract: A method for processing a powder material includes feeding a powder material through an additive processing machine to deposit multiple layers of the powder material onto one another and using an energy beam to thermally fuse selected portions of the layers to one another with reference to data relating to a particular cross-section of an article being formed. The powder material has spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles. The ceramic nanoparticles form a dispersion of reinforcement through the formed article.

Abstract: A feedstock for a cold spray process includes a plurality of globule bodies. The globule bodies include a plurality of discrete particles bonded to one another to define porous globule bodies. The bonds between the particles are of sufficient strength such that the globule bodies can retain both the body integrity as well as the body shape when the body experiences acceleration from a conveying gas in a cold spray technique. Methods of making the feedstock and globule bodies are also described.

Abstract: A brake assembly and a method for manufacturing a brake assembly are provided. The brake assembly includes a brake pad affixed to a substrate. The brake pad extends from the substrate to a brake pad friction surface, and includes abradable cellular metal foam with the hardened ceramic particles.

Abstract: A method for heat treating metal alloy powder includes (a) introducing metal alloy powder to a chamber having a floor and a sidewall; (b) flowing a fluidizing gas through the floor and into the chamber to fluidize the metal alloy powder in the chamber; (c) flowing an additional gas through the sidewall into the chamber; and (d) heating the chamber to heat treat the metal alloy powder in the chamber. A system for heat treating metal alloy powder includes an inner chamber having a porous floor and a porous sidewall; an outer chamber, the inner chamber being inside of the outer chamber and defining an annular space between the outer chamber and the inner chamber, wherein the outer chamber and the inner chamber are inside a furnace; a source of fluidizing gas connected to the porous floor through the annular space; and a source of additional gas communicated with the porous sidewall through the annular space.

Abstract: A thrust plate for a butterfly valve includes a thrust plate body that defines a recess that extends between a bottom thrust surface, side walls, and an open top. There is a nickel-based or cobalt-based wear-resistant coating located on the bottom thrust surface. The wear-resistant coating is harder than the thrust plate body.

Abstract: A carrier gas recovery system for use in cold spray manufacturing recovers carrier gas utilized during the cold spray process and recycles the carrier gas for immediate use or stores the carrier gas for future use. The carrier gas recovery system includes an enclosure subsystem, a filtration subsystem, a reclamation subsystem, and a compensation subsystem. An article is placed in the enclosure and particulate matter is carried to the article on a carrier gas stream. Carrier gas in the enclosure is filtered through the filtration subsystem to remove particulate from the carrier gas, and the filtered carrier gas is fed to the reclamation subsystem. The carrier gas either flows to a gas separator, to increase the concentration of carrier gas, or to the compensation subsystem if the carrier gas concentration is sufficiently high. The carrier gas can be stored in the compensation subsystem or used in further cold spray manufacturing.

Abstract: An erosion resistant and hydrophobic article includes a core that has a first hardness and a surface on the core. The surface includes a plurality of geometric features that have a second, greater hardness. The geometric features define a surface porosity by area percent and a corresponding surface solidity by area percent. The surface includes a ratio of the surface solidity divided by the surface porosity that is 1.8 or greater. The geometric features and the ratio establish the surface to be hydrophobic, and the second, greater hardness and the ratio establish an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions.