US Government As Represented by the Secretary of the Army

Isaac M Nault

Aaron T Nardi

Kenneth Walter Young

Gehn D Ferguson

Marius D Ellingsen

A method of additive manufacturing using cold spray deposition of particles of a material to a supporting surface for deposited material. The method may include providing a cold spray deposition apparatus having a nozzle with a central axis forming an impact angle with the supporting surface and providing an additive material for application to the supporting surface using a cold spray deposition technique. The method may include analyzing characteristics of deposited cold spray material which may include forming a single line of deposited cold spray material on the supporting surface and generating a model of the deposited cold spray material. The method may include selecting a proposed path of movement of the nozzle, predicting results of using the proposed path using the generated model, and modifying the proposed path of movement of the nozzle to reduce error resulting from the proposed path.

Method for cold spray additive manufacturing

A method of determining a tool path for an additive deposition on a surface, the method including receiving primary edges data of the surface of a three-dimensional (3D) object; calculating a number of raster lines for applying an additive deposition on the surface; mapping a raster pattern to the surface of the 3D object; calculating surface normal and rotational angles along the raster lines; calculating a nozzle velocity of an additive application used for producing the additive deposition on the surface; identifying curvature effects of the 3D object; and establishing an order of performing passes of the additive deposition on the surface based on a selected direction for performing the additive deposition and a consideration of a residual stress profile of a resulting deposit.

Growing community of inventors

Bel Air, MD, United States of America

Isaac M Nault