Products and applications for the templated fabrication of materials using cold spray deposition
A product includes an array of cold spray-formed structures. Each of the structures is characterized by having a defined feature size in at least one dimension of less than 100 microns as measured in a plane of deposition of the structure, at least 90% of a theoretical density of a raw material from which the structure is formed, and essentially the same functional properties as the raw material. A product includes a cold spray-formed structure characterized by having a defined feature size in at least one dimension of less than 100 microns as measured in a plane of deposition of the structure, at least 90% of a theoretical density of a raw material from which the structure is formed, and essentially the same functional properties as the raw material.
1. A product, comprising:
an array of cold spray-formed structures formed from a raw material, each of the structures, as-formed, being characterized by having:
a defined feature size in at least one dimension of less than 100 microns as measured in a plane of deposition of the structure,
at least 90% of a theoretical density of the raw material from which the structure is formed, and
essentially the same functional properties as the raw material.
2. The product as recited in claim 1 , wherein a dimension of the array in at least one direction is greater than a radius of spray of a cold spray nozzle used to form the structures.
3. The product as recited in claim 1 , wherein a dimension of the array in at least one direction is greater than 20 mm.
4. The product as recited in claim 1 , wherein at least some of the structures include a change in composition along a thickness thereof.
5. The product as recited in claim 4 , wherein the at least some of the structures are portions of a thermoelectric device, wherein the different compositions are each tailored to a particular temperature operating window.
6. The product as recited in claim 1 , comprising a second array of cold spray-formed second structures interleaved with the structures of the array, the second structures having a different composition than the structures of the array.
7. The product as recited in claim 6 , wherein the array and the second array are part of a thermoelectric device.
8. The product as recited in claim 1 , wherein at least some of the structures have an aspect ratio of orthogonal dimensions in the plane of deposition thereof that is at least 2:1.
9. The product as recited in claim 8 , wherein the at least some of the structures are permanent magnets.
10. The product as recited in claim 8 , wherein the at least some of the structures are part of a superconductor.
11. The product as recited in claim 1 , wherein at least some of the structures are permanent magnets.
12. The product as recited in claim 1 , wherein at least some of the structures are part of a superconductor.
13. The product as recited in claim 1 , wherein at least some of the structures are part of a thermoelectric device.
14. The product as recited in claim 1 , wherein at least some of the structures are part of a piezoelectric device.
15. The product as recited in claim 1 , wherein at least some of the structures are part of a multiferroic device.
16. A product, comprising:
a cold spray-formed structure formed from a raw material, the as-formed cold spray-formed structure characterized by having:
a defined feature size in at least one dimension of less than 100 microns as measured in a plane of deposition of the structure,
at least 90% of a theoretical density of the raw material from which the structure is formed, and
essentially the same functional properties as the raw material.
17. The product as recited in claim 16 , wherein the structure includes a change in composition along a thickness thereof, the structure thereby having portions with differing compositions.
18. The product as recited in claim 17 , wherein the structure is a portion of a thermoelectric device, wherein the different compositions are each tailored to a particular temperature operating window.
19. The product as recited in claim 16 , wherein the structure has an aspect ratio of orthogonal dimensions in the plane of deposition thereof that is at least 2:1.
20. The product as recited in claim 19 , wherein the structure is a permanent magnet.
21. The product as recited in claim 19 , wherein the structure is part of a superconductor.
22. The product as recited in claim 16 , wherein the structure is a permanent magnet.
23. The product as recited in claim 16 , wherein the structure is part of a superconductor.
24. The product as recited in claim 16 , wherein the structure is part of a thermoelectric device.
25. The product as recited in claim 16 , wherein the structure is part of a piezoelectric device.
26. The product as recited in claim 16 , wherein the structure is part of a multiferroic device.