Process for producing a titanium load-bearing structure
A process for producing a titanium load-bearing structure, which comprises cold-gas dynamic spraying of titanium particles on to a suitably shaped support member, and a titanium load bearing structure so-produced.
1. A process for producing a titanium load-bearing structure that could otherwise be produced by welding together individual titanium components, which process comprises cold-gas dynamic spraying of titanium particles on to a support member to form the load-bearing structure as a unitary construction, wherein the shape and configuration of the support member reflects the intended shape and configuration of the load-bearing structure to be produced, and wherein the support member is at least partially removed.
2. The process of claim 1 , wherein after cold-gas dynamic spraying has been completed the support member is removed to produce a free-standing titanium load-bearing structure.
3. The process of claim 2 , wherein the support member is removed by mechanical means or by being dissolved or melted.
4. The process of claim 2 , wherein the support member is removed by relying on differences in thermal expansion coefficients between the titanium and support member.
5. The process of claim 1 , wherein after cold-gas dynamic spraying has been completed the support member is retained at specific locations and removed from other locations of the load-bearing structure.
6. The process of claim 5 , wherein the support member is retained in regions of the load-bearing structure that in use will experience higher load and removed from regions of the load-bearing structure that in use will experience lower load.
7. The process of claim 1 , wherein the titanium that is applied by cold-gas dynamic spraying is of a composition that is varied as cold-gas dynamic spraying proceeds in order to meet location specific load-bearing requirements in the load-bearing structure.
8. The process of claim 1 , wherein the titanium is deposited on the support member with varying thickness based location specific load requirements of the load-bearing structure.
9. The process of claim 1 , wherein the titanium particles have a particle size of from 5 to 40 microns with an average particle size of about 25 microns.
10. The process of claim 1 , wherein the titanium is selected from commercial purity titanium or an alloy of titanium, aluminium and vanadium.
11. The process of claim 1 , wherein the support member is moved relative to a cold-gas dynamic spray nozzle that is used for the cold-gas dynamic spraying.
12. The process of claim 1 , wherein the load-bearing structure is a frame.
13. The process of claim 12 , wherein the frame is a frame for an aerospace vessel, nautical vessel or motor vehicle, or a frame for a bicycle, motorcycle, motor scooter, wheelchair, hang glider or luggage.
14. The process of claim 13 , wherein the frame is a bicycle frame.
15. The process of claim 14 , wherein the support member is formed of aluminium or an aluminium alloy and at least part of the support member is retained following cold-gas dynamic spraying thereby producing a composite load-bearing structure.