A method for forming a metallic structure having a secondary component includes positioning the secondary component on a main formation surface of a main tool, the main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing a layer of material on the secondary component and the main formation surface using a cold-spray technique such that the layer of material bonds to the secondary component. The method also includes removing the layer of material and the secondary component to form the metallic structure.

Disclosed is a cold spray gun and a cold spray apparatus using the same capable of stably heating a raw material powder to a specific high temperature with an achievement of compactness and lightweight of the apparatus. In order to achieve the above described object, there is provided a cold spray gun configured to form a coating film by spraying a raw material powder carried on a carrier gas from a nozzle outlet by a supersonic flow together with a working gas heated to a temperature equal to or lower than a melting point or a softening point of the raw material powder, and causing the raw material powder to collide with a base material in a solid state, the cold spray gun including; a chamber containing the working gas to be delivered to the nozzle; and is characterized in that a gas heating pipe constituted from a heating resistor which causes resistance heating by being energized is arranged in the chamber, and the working gas flowing into the interior of the gas heating pipe is heated.

Disclosed is a cold spray gun and a cold spray apparatus using the same capable of stably heating a raw material powder to a specific high temperature with an achievement of compactness and lightweight of the apparatus. In order to achieve the above described object, there is provided a cold spray gun configured to form a coating film by spraying a raw material powder carried on a carrier gas from a nozzle outlet by a supersonic flow together with a working gas heated to a temperature equal to or lower than a melting point or a softening point of the raw material powder, and causing the raw material powder to collide with a base material in a solid state, the cold spray gun including; a chamber containing the working gas to be delivered to the nozzle; and is characterized in that a gas heating pipe constituted from a heating resistor which causes resistance heating by being energized is arranged in the chamber, and the working gas flowing into the interior of the gas heating pipe is heated.

Aluminum alloys, fabricated by a rapid solidification process, with high strength, high ductility, high corrosion resistance, high creep resistance, and good weldability.

Aluminum alloys, fabricated by a rapid solidification process, with high strength, high ductility, high corrosion resistance, high creep resistance, and good weldability.

In a method of manufacturing a power module unit, cooling fins are positioned in recesses of a frame, in particular a metal frame. A first metallic material is applied to the cooling fins and the frame by a thermal spraying process, causing the applied first metallic material to produce a material bond between the cooling fins and the frame.

A coating method for coating parts in a dip-spin process is provided. The parts to be coated are dipped into a coating liquid and then centrifuged in at least one planetary basket arrangement in a planetary centrifuge. The planetary centrifuge includes a main rotor rotating about a main rotor axis of rotation and at least one planetary basket arrangement rotates about its planetary axis of rotation. Also, the planetary axis of rotation is arranged eccentrically on the main rotor. The at least one planetary basket arrangement can include a plurality of planetary baskets rotatably arranged about the planetary rotation axis of the at least one planetary basket arrangement and the planetary basket arrangement is rotated during a centrifuging operation.

A contact assembly for an electrical device and a method for making such an assembly are presented. The contact assembly comprises a substrate and a contact material disposed on the substrate. The contact material comprises a composite material comprising a refractory material and a matrix material. The matrix material has a higher ductility than the refractory material. The composite material further comprises a core region and an outer region bounding the core region, the core region having a higher concentration of the refractory material than the outer region. The method applies cold spraying a blended feedstock to produce a layer that includes the composite material described above.

A contact assembly for an electrical device and a method for making such an assembly are presented. The contact assembly comprises a substrate and a contact material disposed on the substrate. The contact material comprises a composite material comprising a refractory material and a matrix material. The matrix material has a higher ductility than the refractory material. The composite material further comprises a core region and an outer region bounding the core region, the core region having a higher concentration of the refractory material than the outer region. The method applies cold spraying a blended feedstock to produce a layer that includes the composite material described above.

The disclosure includes manufacturing a semimanufactured cylinder head (3) having a shielding curtain portion (16g) and spraying metal powder (P) onto an annular valve seat portion (16f) using a cold spray method to form a valve seat film (16b). The shielding curtain portion (16g) projects in an annular shape from an annular edge portion of an opening portion (16a) of an intake port (16) or an opening portion (17a) of an exhaust port (17) toward the center (C) of the port. The annular valve seat portion (16f) is located on an outer side of the port than the shielding curtain portion (16g).