Invention Grant
- Patent Title: Systems, methods, and products for creating gas atomized metal matrix composite-based feedstock for cold spray background
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Application No.: US18297271Application Date: 2023-04-07
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Publication No.: US11980944B2Publication Date: 2024-05-14
- Inventor: Bruno Zamorano Senderos , Ali Yousefiani , Michael B. Nicholas , Rogie I. Rodriguez
- Applicant: The Boeing Company
- Applicant Address: US VA Arlington
- Assignee: The Boeing Company
- Current Assignee: The Boeing Company
- Current Assignee Address: US VA Arlington
- Agency: Jordan IP Law, LLC
- The original application number of the division: US16698730 2019.11.27
- Main IPC: B22F9/08
- IPC: B22F9/08 ; C22C1/051

Abstract:
Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles. GAMMC-based feedstock strengthens the repaired part and prevents degradation of the mechanical properties of the repaired part below stock specifications.
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