Abstract: A thermal spray coating composition comprising up to about 90 weight percent of the composition of a first thermoplastic material and up to about 50 weight percent of the composition of at least one additional thermoplastic material that is different from the first thermoplastic material. Additional components can be added to the empirical compositions in order to best additional secondary properties.

Abstract: A coating composition comprising (i) at least one resin powder and (ii) at least one component selected from the group consisting of a metal compound, biocide and fluoropolymers. In particular, one antifouling composition that can be used on underwater stationary structures that sit in highly fouling environments comprises polyethylene as a resin powder, and copper in the form of cuprous or cupric oxide.

Abstract: A particle for depositing a coating on a substrate surface by a low temperature thermal spray process having a plastic core and a particulate forming an non-continuous cladding layer around the plastic core so that enough heat can be transferred to the plastic core to cause it to melt but not so much so as to vaporize the plastic core. At the same time the particulate cladding material having a higher melting point does not melt. A particle having an inorganic core clad to a plastic outer layer is also provided. A process for making the clad material and for thermally spraying the clad material is provided. An article coated with the clad material is also provided.

Abstract: A thermal spray coating composition comprising up to about 90 weight percent of the composition of a first thermoplastic material and up to about 50 weight percent of the composition of at least one additional thermoplastic material that is different from the first thermoplastic material. Additional components can be added to the empirical compositions in order to best additional secondary properties.

Abstract: A high temperature thermal sprayable material, such as a metal or metal oxide, is adhered to the surface of a thermal sprayable plastic particle to form a cladding layer thereon. The high temperature material cladding layer provides a thermal barrier that allows use of the plastic in a high temperature thermal spray process to create a duplex coating containing plastic.

Abstract: A high temperature thermal sprayable material, such as a metal or metal oxide, is adhered to the surface of a thermal sprayable plastic particle to form a cladding layer thereon. The high temperature material cladding layer provides a thermal barrier that allows use of the plastic in a high temperature thermal spray process to create a duplex coating containing plastic.

Abstract: A high temperature thermal sprayable material, such as a metal or metal oxide, is adhered to the surface of a thermal sprayable plastic particle to form a cladding layer thereon. The high temperature material cladding layer provides a thermal barrier that allows use of the plastic in a high temperature thermal spray process to create a duplex coating containing plastic.

Abstract: An improved thermal sprayable molybdenum-iron alloy powder useful for forming wear and abrasion resistant coatings having high thermal conductivity and preferably good corrosion resistance. The preferred embodiment of the alloy powder includes two distinct substantially uniformly dispersed solid solution phases of molybdenum, including a first low molybdenum concentration matrix phase and a second higher molybdenum concentration phase for forming improved dual phase molybdenum coatings. The preferred alloy powder composition includes 15-60% by weight molybdenum, 20-60% by weight iron and the preferred corrosion resistant alloy includes 3-35% by weight nickel plus chromium. A more preferred composition includes by weight 25-50% molybdenum, 4-10% chromium, 10-18% nickel and 1-3% carbon, plus silicon as required to promote fluidity and atomization. The most preferred composition comprises by weight 25-40% molybdenum, 4 to 8% chromium, 12 to 18% nickel, 1-2.5% carbon, 2-3% silicon, 0.2-1% boron and 25-50% iron.

Abstract: A composite wire useful for arc gun spraying is formed of an alloy sheath comprising iron, nickel, or cobalt, and a core comprising boron-containing powder of boron and/or boron carbide sufficiently fine in size such that the boron is substantially dissolved in a coating produced by arc gun spraying the composite wire. Where the boron substance includes boron, the core should further comprise fine carbon powder less than 20 microns in size blended with the boron powder. Preferably a substantial portion of the boron-containing powder is less than 20 microns. In a particularly desirable embodiment, the sheath is formed of mild steel and the core comprises boron carbide and an alloy powder such as ferromolybdenum.

Abstract: A hollow sphere ceramic flame spray powder is disclosed. The desired constituents are first formed into agglomerated particles in a spray drier. Then the agglomerated particles are introduced into a plasma flame which is adjusted so that the particles collected are substantially hollow. The hollow sphere ceramic particles are suitable for flame spraying a porous and abradable coating. The hollow particles may be selected from the group consisting of zirconium oxide and magnesium zirconate.

Abstract: A flame sprayable powder composition suitable for coating a plastic substrate comprising by weight (a) about 90 to 98% of a flame sprayable mineral powder, (b) about 1 to 5% of a nylon powder, and (c) about 1 to 5% of an epoxy resin powder. The coated plastic may thereafter be overcoated by flame spraying with conventional metal or ceramic powders. The undercoat results in a good bond to the substrate.

Abstract: A composite flame spray powder comprising powder particles having as components, cast iron, molybdenum (as such and/or as ferromolybdenum), and boron (as such and/or as ferroboron), unalloyed together. The composite particles are preferably in a form having a cast iron core, of a size between -170 mesh standard screen size and +15 microns, with particles of molybdenum and boron of a size between about -20 and +0.1 microns, bound to the surface of the cast iron core with a binder, the molybdenum being present in amounts of about 20% by weight and the boron in amounts of about 1% by weight based on the total of the cast iron and molybdenum. When flame sprayed, the composite particles produce a coating having high wear and scuff resistance characteristics and low friction.