Cold Spray Deposition with Pulsed Laser Sintering

Abstract

A material deposition method is provided for depositing a layer of a first material onto a substrate composed of a second material. The method includes accelerating an inert gas through a nozzle as a supersonic jet; inserting a powder of the first material into the nozzle; directing said jet with the powder towards the substrate to produce a film of the first material onto the substrate; and aiming a coherent electromagnetic beam from a laser towards the substrate to sinter the film into the layer. The first material can be Inconel 625 or a refractive high entropy alloy.

What is claimed is: 
     
         1 . A material deposition method for providing a layer of a first material onto a substrate composed of a second material, said method comprising:
 accelerating an inert gas through a nozzle as a supersonic jet;   inserting a powder of the first material into said nozzle;   directing said jet with said powder towards the substrate to produce a film of the first material onto the substrate; and   aiming a coherent electromagnetic beam from a laser towards the substrate to sinter said film into the layer.   
     
     
         2 . The method according to  claim 1 , wherein the first material has a higher melting point temperature than the second material. 
     
     
         3 . The method according to  claim 1 , further including heating said inert gas prior to accelerating. 
     
     
         4 . The method according to  claim 1 , wherein the first material is Inconel 625. 
     
     
         5 . The method according to  claim 1 , wherein the first material is a refractive high entropy alloy. 
     
     
         6 . The method according to  claim 5 , wherein the first material is tungsten-tantalum-niobium-molybdenium (WTaNbMo). 
     
     
         7 . The method according to  claim 1 , further including pulsing said electromagnetic beam during aiming.