A method may include cold spraying a masking material on selected locations of a component to form a masking layer, wherein the masking material comprises a metal or alloy; additively manufacturing an additively manufactured portion of the component at locations at which the masking layer is not present; and removing the masking layer from the component. The masking layer may be configured to protect portions of the component by covering or otherwise providing a physical barrier that reduces or prevents material from adhering to unwanted portions of the component during a subsequent manufacturing and/or repair technique. Additionally, the masking layer may be reflective to infrared radiation and/or intimately contact the component and function as a heat sink or thermally conductive layer to transfer heat from the component.

A method may include cold spraying a masking material on selected locations of a component to form a masking layer, wherein the masking material comprises a metal or alloy; additively manufacturing an additively manufactured portion of the component at locations at which the masking layer is not present; and removing the masking layer from the component. The masking layer may be configured to protect portions of the component by covering or otherwise providing a physical barrier that reduces or prevents material from adhering to unwanted portions of the component during a subsequent manufacturing and/or repair technique. Additionally, the masking layer may be reflective to infrared radiation and/or intimately contact the component and function as a heat sink or thermally conductive layer to transfer heat from the component.

A method for making a brake disc may include providing a disc brake with a braking band and depositing on the disc a layer of chromium carbide and nickel-chromium in particle form to form a base protective coating. The method may also include depositing on the base protective coating a material in particle form consisting of tungsten carbide, iron, chromium and aluminium to form a surface protective coating made of tungsten carbide, iron, chromium and aluminium. Both protective coatings may be made by High Velocity Oxygen Fuel or High Velocity Air Fuel or Kinetic Metallization techniques.

A method for making a brake disc may include providing a disc brake with a braking band and depositing on the disc a layer of chromium carbide and nickel-chromium in particle form to form a base protective coating. The method may also include depositing on the base protective coating a material in particle form consisting of tungsten carbide, iron, chromium and aluminium to form a surface protective coating made of tungsten carbide, iron, chromium and aluminium. Both protective coatings may be made by High Velocity Oxygen Fuel or High Velocity Air Fuel or Kinetic Metallization techniques.

A method for manufacturing a planet gear or a sun gear of a gearbox of a wind turbine includes forming a base of the planet gear via at least one of casting or forging. The base of the planet gear includes an inner circumferential surface and an outer circumferential surface. Therefore, at least one of the inner circumferential surface or the outer circumferential surface of the planet gear includes a plurality of net or near-net gear teeth. The method also includes applying a coating material to at least a portion of the base of the gear and at least a portion of the plurality of gear teeth of the gear via an additive manufacturing process so as to increase a hardness of the portions of the base and the plurality of gear teeth that includes the coating material.

A testing arrangement and method of using in performing an in-situ adhesion test of a cold spray deposit on a surface of a structure. The testing arrangement includes a specimen member having a number of apertures defined therein and a loading arrangement coupled to the specimen member. The loading arrangement is configured to provide a mechanical force of a known magnitude to the specimen member. In performing an in-situ test of a cold spray deposit on a structure, the method includes positioning the testing arrangement with respect to a surface of the structure, depositing the cold spray deposit on the surface of the structure, and testing the adhesion of the cold spray deposit to the surface.

A testing arrangement and method of using in performing an in-situ adhesion test of a cold spray deposit on a surface of a structure. The testing arrangement includes a specimen member having a number of apertures defined therein and a loading arrangement coupled to the specimen member. The loading arrangement is configured to provide a mechanical force of a known magnitude to the specimen member. In performing an in-situ test of a cold spray deposit on a structure, the method includes positioning the testing arrangement with respect to a surface of the structure, depositing the cold spray deposit on the surface of the structure, and testing the adhesion of the cold spray deposit to the surface.

A method for forming a reinforced metallic structure includes providing a tool having a formation surface corresponding to a desired structure shape of the reinforced metallic structure. The method also includes positioning a plurality of fibers on the formation surface of the tool. The method also includes depositing a layer of material on the plurality of fibers using a cold-spray technique. The method also includes removing the layer of material with the plurality of fibers from the tool to create the reinforced metallic structure.

A method for forming a reinforced metallic structure includes providing a tool having a formation surface corresponding to a desired structure shape of the reinforced metallic structure. The method also includes positioning a plurality of fibers on the formation surface of the tool. The method also includes depositing a layer of material on the plurality of fibers using a cold-spray technique. The method also includes removing the layer of material with the plurality of fibers from the tool to create the reinforced metallic structure.

The present invention relates to an interface-forming device (x60) and a method for providing an electrically conductive power transmission interface (x30) on the end surface of a power cable (xOO) having at least two separate wires (x02) being electrically conductive, the cable (xOO) further comprising a reactive compound different from the wires (x02) for providing further features to the power cable (xOO). The method comprises the steps of providing an end section of the power cable (xOO), the end section comprising wires (x02) having wire ends, the end section further having the reactive compound, and successively adding electrically conductive particulates (x67A) onto the end section by bringing the conductive particulates being dispersed in a carrier fluid of a different material than the conductive particulates into contact with the end section. Thereby, cable joining and terminations are achieved of a higher quality.