Abstract: A spool support assembly for supporting the wire spools for a thermal spray gun, the assembly including a stand having a pair of axially aligned keyed openings, a bolt aligned in the openings and having a keyway matingly engaging the keyed opening, a hub mounted on the bolt on each side of the stand for supporting the wire spools, a spring mounted on the bolt on the outer end of the hubs and a nut provided on one end of the bolt for simultaneously adjusting the compressive force of the springs to maintain the same tension on the wires between the spools and the thermal spray gun.

Abstract: A dual switch for a semi automatic welding gun has a switch lever that pivots between three positions. At the first position, the switch lever is disengaged from a first switch so that the welding gun is "off". In the second position, the switch lever engages the first switch to turn the gun "on". A locking lever retains the switch lever in its second position. Pivoting the switch lever to its third position releases the locking lever to enable the switch lever to return, under a spring bias, to its first position. A second switch is independent of the first switch and is selectively actuated to vary the welding schedule while the gun is either "on" or "off".

Abstract: A self-contained welding machine has the same width as a selected prior welding machine and is interchangeably mountable therewith to a flat surface. The welding machine of the invention has a base that utilizes the full space available above its width by fabricating the base with side walls that lie in respective vertical planes coinciding with the vertical planes that pass through the outermost ends of mounting lugs on the base of the prior welding machine. Mounting holes in the floor of the base are accessible through associated openings in the base side walls. Covers cooperate with the base floor and side walls to create pockets that close the side wall openings while providing access to the mounting holes in the base floor.

Abstract: At end cap construction forms part of an enclosure for a self-contained welding machine. The end cap construction comprises a control panel assembled to the back plane of an upright bezel. Triangular-shaped arms on the bezel fit into a corresponding triangular-shaped outline of the panel to add rigidity to the panel. The bezel has appreciable thickness between its back plane and a front plane. Control knobs on the control panel front surface are recessed from the bezel front plane and are thus protected by the bezel against damage. The bezel and panel have respective flanges that are fastened to top and side covers that complete the enclosure.

Abstract: An idle solenoid assembly sets the idle speed of the internal combustion engine of a self-contained welding machine. The idle solenoid assembly comprises a bracket to which a solenoid is immovably secured. The solenoid plunger is connected to the engine governor arm. The bracket has slotted feet that slide on an engine surface. By sliding the bracket, the position of the engine governor arm is adjusted to produce the desired engine idle speed when the solenoid is actuated. There is no contact or binding between the bracket and the solenoid plunger or between the solenoid plunger and the engine governor arm. The solenoid is wired to a control circuit through a first plug retained in the bracket and a second plug. The solenoid is properly grounded on the internal combustion engine through the second plug.

Abstract: A method and apparatus for initiating arc spraying is disclosed. The invention includes feeding the wires to an arc at a predetermined rate, for a predetermined length of time. Thereafter the wires are fed at a rate which is controlled in response to the current magnitude. The arc is also monitored and the condition of the arc--whether there is a shortage or outage--is indicated to the user.

Abstract: A method and apparatus for arc spraying a pair of wires is disclosed. The invention includes feeding the wires to an arc at a controllable rate, where the rate is controlled in response to the current magnitude, or some other parameter of the arc. The arc is also monitored and the condition of the arc--whether there is a wire shortage or arc outage--is indicated to the user.