Abstract: A wire arc spray system (100) includes a plurality of arc spray subsystems (130) mounted to a movable carriage (120) on an x-y robot (110). Each arc spray subsystem includes a wire drive (132) that provides wire (133, 134) to a spray head (138) through a pair of lead cables (136). The spray heads are mounted for circular motion, such that the molten spray is applied to an underlying substrate in a swirling pattern. In one embodiment, the spray heads are mounted to a distal end of a rod (164) that extends through a swivel ball joint (166) and engages an eccentric link (162) fixed to a motor (160). The system applies an overlapping pattern of molten spray to provide excellent non-skid and adhesion properties. The system is particularly suited to spray coating with a wire comprising a hollow metallic portion and a core having ceramic particles.

Abstract: A process, whereas, the wire feed motor of the of twin wire arc spray process, receives its power from the same power circuit that creates the arc spray operation, thereby automatically changing the wire feed rate, as voltage changes occur in the spray process. Thereby maintaining a constant arc gap and consistent atomization to produce a uniform coating with no arc shorting. As the spray operation voltage decreases (attempting to close the wire gap) the wire feed decreases to maintain the wire gap. Conversely, when the voltage increases (attempting to open the wire gap) the wire feed increases to maintain the wire gap. Additionally, an automatic start up process is included in the present invention, a method is implored to reverse the wires at system start up to create a gap between the wires, this allows an arc to generate.

Abstract: A process, whereas, the wire feed motor of the of twin wire arc spray process, receives its power from the same power circuit that creates the arc spray operation, thereby automatically changing the wire feed rate, as voltage changes occur in the spray process. Thereby maintaining a constant arc gap and consistent atomization to produce a uniform coating with no arc shorting. As the spray operation voltage decreases (attempting to close the wire gap) the wire feed decreases to maintain the wire gap. Conversely, when the voltage increases (attempting to open the wire gap) the wire feed increases to maintain the wire gap. Additionally, an automatic start up process is included in the present invention, a method is implored to reverse the wires at system start up to create a gap between the wires, this allows an arc to generate.

Abstract: A process for creating a coating that protects the underlying article from corrosion and provides a surface that prolongs service life against wear, such as, adhesion, abrasion, erosion, fretting and also can provide non-slip properties for person walking, standing, working on and vehicles traveling on. A hollow wire made of aluminum, or aluminum alloy, or zinc, or zinc alloy, filled with wear resistant particles, such as, oxides or carbides, then thermally metal sprayed onto a substrate of iron alloy, e.g. steel, or aluminum alloy, creates a coating with wear resistant properties that also provides corrosion protection to the substrate. A hollow wire of aluminum or aluminum alloy filled with wear resistant particles then welded to an aluminum alloy, provide a metallurgical compatible coating with wear resistant properties.

Abstract: An arc spray bead for uniformly distributing molten metal. The head includes a pair of contact tips, a primary nozzle and a plurality of side nozzles. Wire is fed through the contact tips into an arc zone where the wire tips are melted. The plurality of side nozzles are located adjacent to the contact tips downstream from the primary nozzle. The primary nozzle blows the molten metal into the stream of the side nozzles. The nozzles atomize, cool and uniformly distribute the molten metal into a desired spray pattern. During spraying the feed wires are moved forward. Initially upon discontinuing the spraying, the feed wires are retracted in part to prevent fusing of the wire leads.

Abstract: The plasma-arc torch is of the type wherein a thermally ionizable gas is ected past a non-consumable cathode electrode and through the constricted orifice of a nozzle. An arc is established between the non-consumable electrode and the nozzle to initiate and sustain a plasma stream through the constricted orifice and then through a final port in a housing. A shield gas is directed around the nozzle and through the final port in the housing. A wire guide/contact tip is used for supporting a positively charged spray wire with a wire alignment fixture for coupling the wire guide/contact tip to the plasma stream outside the final port in the housing, the wire alignment fixture having a first collar section fixed to the torch and a second collar section fixed to the wire guide/contact tip.

Abstract: An apparatus and method for spraying molten metal that is light weight, requires low maintenance and is quick and simple to operate. A feed system is provided that uses an electric motor and control system to push the electrodes to the head and to prevent system failure, by temporarily stopping the feed, upon the occurrence of the feed wires becoming shorted or welded together. A portable head is provided that employs parallel lead guides that allows complete head manipulation without electrode mismatch. An atomizing gas nozzle is also provided that permits lower air pressure and compensates for arc wander. A lead system is provided that combines into one lead the feed wire guides, current leads and the atomizing gas. The atomizing gas also becomes a cooland allowing lighter current leads for arc metal spraying.

Abstract: An apparatus and method for spraying molten metal that is light weight, requires low maintenance and is quick and simple to operate. A feed system is provided that uses an electric motor and control system to push the electrodes to the head and to prevent system failure, by temporarily stopping the feed, upon the occurrence of the feed wires becoming shorted or welded together. A portable head is provided that employs parallel lead guides that allows complete head manipulation without electrode mismatch. An atomizing gas nozzle is also provided that permits lower air pressure and compensates for arc wander. A lead system is provided that combines into one lead the feed wire guides, current leads and the atomizing gas. The atomizing gas also becomes a coolant allowing lighter current leads for arc metal spraying.