Abstract: A spray apparatus includes a body having an outer surface and an interior portion, and a first nozzle arranged in the interior portion of the body. The first nozzle includes a first material inlet, a first convergent region, a first throat region, a first divergent region, and a first outlet. The first throat region and first outlet establish a first expansion ratio. A second nozzle is arranged in the interior portion of the body adjacent the first nozzle. The second nozzle includes a second material inlet, a second convergent region, a second throat region, a second divergent region, and a second outlet. The second throat region and the second outlet establish a second expansion ratio that is distinct from the first expansion ratio.

Abstract: Disclosed is a coating, a turbine component, and a process of fabricating a turbine component. The coating includes a ceramic phase formed by ceramic particles and a ductile matrix having a ductility greater than the ceramic phase. The ceramic phase includes substantially the same microstructure as the ceramic particles. The turbine component includes a surface having the coating. The process includes applying the coating to the surface of the turbine component.

Abstract: A process for applying a hard coating to a turbine rotor comprising providing a turbine rotor having at least one surface; applying a first coating to the at least one surface, the first coating being cold sprayed onto the at least one surface; applying a second coating onto the first coating to form the hard coating, wherein the hard coating is configured to substantially resist wear of a brush seal in physical communication with the turbine rotor.

Abstract: A process for applying a bond coat layer to a substrate includes cold spraying a first powdered material onto a surface of the substrate at a first velocity, wherein the first powdered material has a first particle size distribution; and cold spraying a second powdered material onto the surface at a second velocity to form the bond coat layer, wherein the second powdered material has a second particle size distribution and the bond coat layer comprises a microstructure comprising at least the first and second particle sizes.

Abstract: An enclosure system is provided having a shroud configured to cover at least a portion of a shaft. The shroud includes an input port and an output port. The input port is configured to accept at least one of a coating tool and an abrasive supplying tool. The output port is connected to a vacuum system.

Abstract: A process of applying a porous metallic structure and a cold-sprayed article are disclosed. The process includes cold spraying a solid feedstock and a low-melt material onto an article and removing at least a portion of the low-melt materials or applying a porous metallic structure includes cold spraying onto an article with two converging-diverging nozzles. The cold-sprayed article includes a porous metallic structure having a portion formed from cold spraying a solid feedstock. The portion includes the phases and microstructure of the solid feedstock.

Abstract: A coating composition, a process of applying a coating having a coating composition, and a process of forming a coating composition are disclosed. The coating composition includes an alloy and an oxide component comprising nickel oxide. The process of applying the coating includes cold spraying the coating onto the article. The process of forming the coating composition includes blending and milling the alloy with the oxide component.

Abstract: A spray apparatus includes a body having an outer surface and an interior portion, and a first nozzle arranged in the interior portion of the body. The first nozzle includes a first material inlet, a first convergent region, a first throat region, a first divergent region, and a first outlet. The first throat region and first outlet establish a first expansion ratio. A second nozzle is arranged in the interior portion of the body adjacent the first nozzle. The second nozzle includes a second material inlet, a second convergent region, a second throat region, a second divergent region, and a second outlet. The second throat region and the second outlet establish a second expansion ratio that is distinct from the first expansion ratio.

Abstract: A method of repairing a damaged rotor comprising: (a) preparing a locally damaged portion of the rotor; (b) cold spraying alloy powder particles onto the locally damaged portion; (c) controlling the cold spraying in step (b) to restore the locally damaged portion to form a repaired portion having substantially the same properties and shape as originally manufactured; and (d) heat treating at least the repaired portion.

Abstract: A method of coating a substrate with cryo-milled, nano-grained particles includes forming a face-centered-cubic gamma matrix comprising nickel, cobalt, chromium, tungsten and molybdenum, adding a dispersion strengthening material to the gamma matrix to form a first mixture, cryo-milling the first mixture to form a second mixture to form a nano-grained structure, and cold spraying the second mixture onto a substrate to form a coating having a nano-grained structure.

Abstract: A method of manufacturing a rotor includes: (a) providing a core shaft; (b) cold spraying alloy powder particles onto the core shaft; (c) controlling the cold spraying to form sections at least of different shape along the core shaft to thereby form a near-net shape rotor; and (d) heat treating the near-net shape rotor to relieve stresses and to form diffusion bonding across interfaces between individual powder particles and the core shaft, and finish-shaping said near-net shape rotor.

Abstract: A nozzle for use with a spray coating gun for applying a coating material to a substrate. The nozzle includes a discharge portion operative to emit the coating material therefrom. The nozzle also includes a material-receiving portion operative to receive feedstock therein. The discharge portion is angled from the material-receiving portion such that the coating material is discharged from the discharge portion and impacts and bonds with a region of the substrate. The discharge portion can be positioned to apply the coating material in various locations.

Abstract: A spray coating process and apparatus suitable for depositing coatings on surfaces of components, and particularly surfaces that are difficult to access with conventional cold spraying equipment. The process and apparatus employ a spray gun having a tubular body with a longitudinal axis and an exit at one end thereof. The body has a first portion defining a converging passage, a second portion defining a diverging passage that defines the exit of the body, and a throat portion therebetween that defines a throat between and connecting the converging and diverging passages. The gun is further equipped with at least one gas inlet for introducing a gas upstream of the converging passage, and at least one feedstock inlet for introducing a feedstock at or immediately upstream of the throat.

Abstract: A cold spray coating system comprising, a cold spray coating gun having a nozzle member operative to emit a stream of gas and granules of a coating material from a nozzle opening defined by the nozzle member such that the granules of the coating material impact and bond with a first region of a substrate, and a heat source member operative heat the first region of the substrate.

Abstract: A method of manufacturing a rotor includes: (a) providing a core shaft; (b) cold spraying alloy powder particles onto the core shaft; (c) controlling the cold spraying to form sections at least of different shape along the core shaft to thereby form a near-net shape rotor; and (d) heat treating the near-net shape rotor to relieve stresses and to form diffusion bonding across interfaces between individual powder particles and the core shaft, and finish-shaping said near-net shape rotor.

Abstract: A spray coating process and apparatus suitable for depositing coatings on surfaces of components, and particularly surfaces that are difficult to access with conventional cold spraying equipment. The process and apparatus employ a spray gun having a tubular body with a longitudinal axis and an exit at one end thereof. The body has a first portion defining a converging passage, a second portion defining a diverging passage that defines the exit of the body, and a throat portion therebetween that defines a throat between and connecting the converging and diverging passages. The gun is further equipped with at least one gas inlet for introducing a gas upstream of the converging passage, and at least one feedstock inlet for introducing a feedstock at or immediately upstream of the throat.

Abstract: In one embodiment, a system includes a welding controller configured to receive images from multiple observation points directed toward a deposition zone. The welding controller is also configured to control a parameter affecting deposition based on a differential analysis of the images.

Abstract: A method of coating a substrate with cryo-milled, nano-grained particles includes forming a face-centered-cubic gamma matrix comprising nickel, cobalt, chromium, tungsten and molybdenum, adding a dispersion strengthening material to the gamma matrix to form a first mixture, cryo-milling the first mixture to form a second mixture to form a nano-grained structure, and cold spraying the second mixture onto a substrate to form a coating having a nano-grained structure.

Abstract: Systems and methods are disclosed for joining two or more parts together via cold spraying. In one embodiment, a first part and second part may be aligned together to create a joint. The parts are joined by cold spraying a material on the first metal part and the second metal part to create a bond at the joint.

Abstract: A cold spray coating system comprising, a cold spray coating gun having a nozzle member operative to emit a stream of gas and granules of a coating material from a nozzle opening defined by the nozzle member such that the granules of the coating material impact and bond with a first region of a substrate, and a heat source member operative heat the first region of the substrate.