The client came to us with a brand-new design of an engine combustion chamber. The issue they were having was finding a way to hold in the component that injects fuel. This couldn't be welded as there are a differing range of metals and it would cause distortion and cracking. Neither could it be screwed or use an interference fit due to production requirements and differing materials.
Speaking to the client and learning the problems they were having, we knew cold spray could be an ideal solution for them. Because of this we entered into an R&D project to develop and test a cold spray manufacturing method to lock the parts into the casting. This involved designing masking, developing robot programs to fully automate the process and new machining methods to machine back the cold spray. Prototypes were then sent to the client to be tested. Once the cold spray method was proven through a thorough testing programme the client was happy to move into a small production run.
New streamlined production method, reduced component dimensions, introduction of differing materials, excellent heat transfer properties, permanent location even with side by side multi-metals — all with a low heat input CMS process.
Cold Metal Spray now produce a low-volume production run of this new fuelling and combustion design, doing the preparation, cold spray and machining all in-house. At Cold Metal Spray we have fully automated the process making it faster, more efficient and less likely for operator error. Fully automating the process also means it's ready for when production ramps up and easy for the client to meet this demand.
Tell us about your component and we'll advise on the best cold spray solution.