Abstract: A powder feed assembly comprises a powder hopper, a motor, an auger housing, an auger, a porous gas-permeable powder filter, a carrier gas inlet, an auger sleeve, and a powder hose. The auger housing receives a powder from the opening in the hopper floor into a powder chamber defined in the auger housing. The auger is selectively rotatable to propel the powder from the powder chamber past the distal end of the auger and into the auger sleeve. The carrier gas inlet introduces carrier gas into an inner chamber of the auger housing. The wall of the auger sleeve allows at least some of the carrier gas to flow or permeate into the internal bore of the auger sleeve to pick up and carry the propelled powder out of the auger housing. The powder hose directs the carrier gas and carried powder from the auger housing to a powder dispenser.

Abstract: A powder feed assembly comprises a powder hopper and a selectively rotating blade. The powder hopper has a wall and a floor together forming a chamber. A circumferential horizontal gap is defined between the wall and the floor to enable powder to exit the chamber. The selectively rotating blade has a body portion positioned within the chamber and one or more blade portions at least partially extending into the gap.

Abstract: A powder feed assembly comprises a powder hopper and a selectively rotating blade. The powder hopper has a wall and a floor together forming a chamber. A circumferential horizontal gap is defined between the wall and the floor to enable powder to exit the chamber. The selectively rotating blade has a body portion positioned within the chamber and one or more blade portions at least partially extending into the gap.

Abstract: A gas dynamic cold spray gun comprises a gun housing, a permeable body arranged inside the gun housing having a carrier gas inlet at a first end and a carrier gas outlet at a second end, an induction coil surrounding the permeable body and connected to a power supply, a nozzle affixed to the carrier gas outlet of the permeable body, and an orifice located downstream of the nozzle connected to a powder feeder.

Abstract: A method of forming a coating deposits a material onto a substrate with high velocity thermal spray apparatus. The method comprises the steps of mixing of an oxidizer gas and a gaseous fuel in the mixing unit, igniting and combusting the oxidizer and gaseous fuel mixture in the combustion chamber, feeding products of combustion to the accelerating nozzle, introducing selected spraying material into accelerating nozzle to form a supersonic stream of hot combustion product gases with entrained particles of spray material, and spraying at high velocity onto a surface positioned in the path of the stream at the discharge end of the nozzle; and forming a non-clogging convergent-divergent gas dynamic virtual nozzle (GDVN) in the accelerating nozzle by annularly introducing a coaxial gas flow, through a narrow continuous slot of circumferential ring geometry in the vicinity of the entrance to the diverging outlet bore of the accelerating nozzle.