Temperature Measurement of Cold Spray

September 17, 2018 The closing date for this challenge has been extended to September 20, 2018 at 14:00 EDT. ************ This Challenge Notice is issued under the Innovative Solutions Canada Program Call for Proposals (EN578-170003/B). Please refer to the Solicitation Documents which contain the process for submitting a proposal. CHALLENGE TITLE: Temperature Measurement of Cold Spray CHALLENGE SPONSOR: National Research Council (NRC) Steps to apply: Step 1: read this challenge Step 2: read the Call for Proposals Step 3: propose your solution Funding Mechanism: Contract MAXIMUM CONTRACT VALUE: Multiple contracts could result from this Challenge. The maximum funding available for any Phase 1 Contract resulting from this Challenge is $150,000.00 CAD (plus tax) including shipping, travel and living expenses, as applicable. The maximum funding available for any Phase 2 Contract resulting from this Challenge is $1,000,000.00 CAD (plus tax) including shipping, travel and living expenses, as applicable. Only eligible businesses that have completed Phase 1 could be considered for Phase 2. This disclosure is made in good faith and does not commit Canada to contract for the total approximate funding. TRAVEL: For Phase 1 it is anticipated that two meetings will require the successful bidder(s) to travel to the location identified below: i) Kick-off meeting - Montreal, Quebec ii) Final Review Meeting - Montreal, Quebec Problem Summary Statement This challenge seeks to measure in-flight metal particle temperature in a cold spray process. Problem Statement Cold Spray metal deposition is a process whereby metal powder (typically in the size range of 1 to 50 um) is accelerated in a supersonic gas jet. The particles impact a substrate and plastically deform and adhere to the surface to form a coating. Coating properties and performance such as hardness, density, porosity, mechanical properties will depend mainly on the temperature and velocity of the particles upon impact. As such, those two parameters are key for coating optimization and process quality control. Although it is currently possible to measure in-flight particle velocities, there is no available mean to measure in-flight particle temperature. This limits the R&D work that can be done in the field – as researchers have to rely on partial information to develop their theories and to proceed to process optimization. The impossibility to measure in-flight particle temperature also limits the reliability of the process – due to a lack of control. Desired outcomes and Considerations The technology should present the following characteristics: Measurable particle temperature range: Equipment should be able to measure particle temperatures from 25C to 800C. Automated: Technology should be easy to use and deliver meaningful results (at a minimum, measured particle temperature range with mean particle temperature). Safe and convenient: Technology should be easy to install in cold spray booth, with setup time of less than 2 hours. It should be safe to use, i.e. be compliant with Canada Labour Code, Part II, and its associated Canada Occupational Health and Safety Regulations, including being CSA certified. Robust: Technology is expected to work in a dusty cold spray booth. Background and Context Particle in-flight velocity and temperatures are key process parameters of thermal spray technologies, where cold spray pertains. Traditional thermal spray techniques involve heating at high temperature and melting of the feedstock materials. Technologies have been developed to measure in-flight particle temperature and velocity through optical sensors capturing light emitted by the hot particles. In the specific case of cold spray, particles are too cold to emit sufficient amount of radiation (light) for diagnostics. This constraint has been overcome by adding a laser to the diagnostic systems, directed toward the cold spray jet. Laser reflected by the particles is monitored by optical sensors, allowing the calculation of particle velocities. However, since the captured light is originating from a laser, and not emitted by the particle itself, particle temperature cannot be inferred from the detected signal. Canada is world leader in cold spray technology. For the last decade, a unique combination of Academics and Governmental Institutions (National Research Council of Canada) has been developing the process and potential applications. Recently, there has been a noticeable effort in transferring the technology to the industry and generating an adequate supply chain. Several Canadian small and medium-sized enterprises (SMEs) are now positioning themselves as cold spray powder suppliers, integrators or service providers. Several Canadian aerospace original equipment manufacturers (OEMs) also show an interest and are at different stage of cold spray implementation. For many applications, cold spray appears as a cost-effective method for additive manufacturing, repair, and coating deposition. Development of a local solution to the submitted problem would contribute to maintain Canada in its leading position, providing an edge to its advanced manufacturing industry. Innovative Solutions Canada is designed to seek truly novel solutions from Canadian small business. Challenges posted through ISC may appear to provide few details or specifications on what the desired solutions should look like. This is intentional. Challenge statements will contain some guidance on desired outcomes, but will not prescribe how a solution should work or function. We leave that to the creativity and ingenuity of Canada’s innovators. Enquiries All enquiries must be submitted in writing to the Contracting Authority no later than ten calendar days before the Challenge Notice closing date. Enquiries received after that time may not be answered.