Claims
- 1. A process for applying a wear alloy coating to a component, the process comprising:
providing a predetermined mix of particles of a wear alloy material; and cold spraying the particle mix toward a target surface of a substrate material at a velocity sufficiently high to cause the particles to adhere to the target surface.
- 2. The process of claim 1, further comprising providing the predetermined mix of particles to include particles of a carbide material having a predetermined size range.
- 3. The process of claim 1, further comprising providing the predetermined mix of particles to include particles of a wear alloy material and particles of a second material.
- 4. The process of claim 3, further comprising providing the particles of a second material to comprise a lubricant material.
- 5. The process of claim 4, further comprising providing the particles of a second material to comprise graphite.
- 6. The process of claim 5, further comprising providing the particles of a second material to comprise one of the group of graphite and molybdenum disulfide.
- 7. The process of claim 1, further comprising providing the predetermined mix of particles to include molybdenum disulfide.
- 8. The process of claim 1, further comprising providing the particles of a second material to comprise a ceramic material.
- 9. The process of claim 1, further comprising:
selecting the substrate material to comprise one of a single crystal material and a directionally solidified material; cold spraying the particle mix toward the target surface at a velocity sufficiently high to cause the particles to adhere to the target surface without recrystallization of the substrate material.
- 10. The process of claim 1, further comprising controlling at least one of the velocity and a size range of the particle mix to achieve a predetermined surface roughness.
- 11. The process of claim 1, further comprising cold spraying the particle mix toward the target surface proximate a brazed joint at a velocity sufficiently high to cause particles to adhere to the target surface without metallurgical degrading properties of the brazed joint.
- 12. The process of claim 1, further comprising changing a composition of the particle mix during the step of cold spraying to produce a coating having a varying property across its depth.
- 13. The process of claim 1, further comprising changing a size range of the particle mix during the step of cold spraying to produce a coating having a varying property across its depth.
- 14. The process of claim 1, wherein the particle mix comprises carbide particles, and further comprising changing a size range of the carbide particles during the step of cold spraying to produce a coating having a varying property across its depth.
- 15. The process of claim 1, wherein the particle mix comprises a Group 4 or Group 5 hard facing material, and further comprising continuing the step of cold spraying to form a coating of hard facing material having a thickness in excess of 0.25 inch.
- 16. A process for applying a wear alloy coating, the process comprising:
cold spraying particles of a first particle mix comprising a wear alloy material toward a target surface at a velocity sufficiently high to cause the particles to adhere to the target surface to form a first wear alloy coating region; and cold spraying particles of a second particle mix different than the first particle mix toward a surface of the first wear alloy coating region at a velocity sufficiently high to cause the particles to adhere to the first wear alloy coating layer to form a second wear alloy coating region.
- 17. The process of claim 16, wherein the first wear alloy coating region is a layer distinct from the second wear alloy coating region.
- 18. The process of claim 16, wherein the first wear alloy coating region and the second wear alloy coating region are regions of graduated layer of wear alloy coating.
- 19. The process of claim 16, further comprising selecting the first particle mix to comprise particles having a different composition than particles of the second particle mix.
- 20. The process of claim 16, further comprising selecting the first particle mix to comprise particles having a different size range than particles of the second particle mix.
- 21. The process of claim 16, further comprising selecting the first particle mix to comprise particles of a carbide having a different size range than carbide particles of the second particle mix.
- 22. The process of claim 16, further comprising selecting the first particle mix to comprise a concentration of particles of a carbide different than a concentration of particles of a carbide of the second particle mix.
- 23. The process of claim 16, further comprising selecting the first particle mix to comprise a concentration of particles of a lubricant material different than a concentration of particles of a lubricant material of the second particle mix.
- 24. A coating for a component surface, the coating material comprising particles of a wear alloy material and particles of a second material different than the wear alloy material applied to the component surface by a cold spray process.
- 25. The coating of claim 24, wherein a concentration of the second material relative to the wear alloy material varies across a depth of the coating.
- 26. The coating of claim 24, wherein a size range of the particles of the second material varies across a depth of the coating.
- 27. The coating of claim 24, wherein the second material comprises a lubricant material.
- 28. The wear alloy coating of claim 27, wherein the second material comprises one of the group of graphite and molybdenum disulfide.
- 29. The coating of claim 24, wherein the second material comprises a ceramic material.
- 30. The coating of claim 24, wherein the wear alloy material comprises one of a Group 4 hard facing material and a Group 5 hard facing material and the second material comprises a lubricant.
Parent Case Info
[0001] This application claims benefit of the Aug. 1, 2001, filing date of U.S. provisional patent application No. 60/309,451; and further the Dec. 5, 2001, filing date of U.S. provisional patent application No. 60/336,825; and further the Jan. 30, 2001, filing date of U.S. patent application Ser. No. 09/774,550; and further the Dec. 5, 2000, filing date of U.S. patent application Ser. No. 09/729,844.
Provisional Applications (2)
|
Number |
Date |
Country |
|
60309451 |
Aug 2001 |
US |
|
60336825 |
Dec 2001 |
US |