Abstract: Interchangeable or standard electrode interface for a thermal spray plasma gun includes an interchangeable electrode having a first connecting section and a first annular coupling surface. A second connecting section is arranged in a plasma gun and includes a second annular coupling surface. An annular seal is spaced or axially spaced from an annular interface formed between the first and second annular coupling surfaces.

Abstract: Plume shield shroud (10) for a plasma gun (30) includes a substantially tubular member (14) comprising an axial length, a plume entry end (11), and a plume exit end (13). The shroud (10) is adapted to be mounted to a plasma gun (30). A method of protecting, confining or shielding of a gas plume of a plasma gun (30) includes mounting (20) a gas plume shroud (10) on the plasma gun (30) such that the shroud (10) is sized and configured to substantially surround at least a portion of the gas plume.

Abstract: Water cooling system (1) for a plasma gun (2), method for cooling a plasma gun (2) and method for increasing a service life of a plasma gun (2). The system (1) includes a water cooler structured and arranged to remove heat from cooling water to be supplied to the plasma gun (2), a controller (7) structured and arranged to monitor a gun voltage of the plasma gun (2), and at least one flow valve (8) coupled to and under control of the controller (7) to adjust a flow of the cooling water. When the gun voltage drops below a predetermined value, the controller (7) controls the at least one flow valve (8) to increase the plasma gun temperature and the gun voltage.

Abstract: A thermo spray gun (10) includes at least one of; at least one removable nozzle tip (20) for spraying a coating material, at least one replaceable nozzle tip (20) for spraying a coating material, and at least one interchangeable nozzle tip (20) for spraying a coating material. A thermo spray gun system (1000) includes a thermal spray gun (10) and at least one mechanism (30/40) at least one of; storing at least one nozzle tip installable on the thermal spray gun and being structured and arranged to install at least one nozzle tip on the thermal spray gun. A method of coating a substrate (S) using a thermo spray gun (10) includes mounting at least one nozzle tip (20) on the thermo spray gun (10) and spraying a coating material with the at least one nozzle tip (20).

Abstract: Plasma gun and method of applying powder to a substrate with a plasma gun. The plasma gun includes a cathode assembly (1), an anode (2), a rear neutrode (7), and an extended neutrode (8) positioned adjacent the rear neutrode (7) to define a channel bore (3) between the cathode assembly (1) and the anode (2). The extended neutrode (8) has a length greater than 38 mm. The plasma gun can also include at least one gas inlet to supply a gas to the channel bore (3) and a power supply.

Abstract: Interchangeable or standard electrode interface for a thermal spray plasma gun includes an interchangeable electrode having a first connecting section and a first annular coupling surface. A second connecting section is arranged in a plasma gun and includes a second annular coupling surface. An annular seal is spaced or axially spaced from an annular interface formed between the first and second annular coupling surfaces.

Abstract: Coatings on a substrate and application methods result in coatings that can withstand different types or groups of bulk cargo and operations. This novel approach includes use of a combination of layers of coating materials at certain thicknesses and applied with certain techniques. In certain embodiments, the coating system includes coatings applied to a pretreated substrate, e.g., blasted steel cargo hold plates of an oceangoing vessel. The coatings include a bond layer and a resistance layer, e.g., an anti-corrosive layer tailored to resist at least one of corrosion, erosion, impact and wear of the substrate.

Abstract: A two stage kinetic energy spray device has a first stage first nozzle having a receiving end that receives a particulate stream, an injection end located axially to the first nozzle receiving end, the injection end receiving the particulate stream from the receiving end. A second stage has a second nozzle, the second nozzle having a gas receiving portion that receives an effluent gas, a convergent portion that is downstream from the gas receiving portion and a divergent portion that is downstream from the convergent portion, the convergent portion and the divergent portion meeting at a throat. The particle stream is accelerated to a first velocity in the first nozzle located within the second nozzle divergent portion The effluent gas is accelerated to a second velocity in the second nozzle. First nozzle injection end chevrons allow mixing of particulate and supersonic effluent streams prior to exiting the spray device.

Abstract: An apparatus for and a method of prepping a surface of a cylinder bore using a pulsed waterjet entails generating a signal having a frequency f using a signal generator, applying the signal to generate a pulsed waterjet through an exit orifice of a nozzle having an exit orifice diameter d and a length L. The pulsed waterjet prepares the surface to within a predetermined range of surface roughness. The surface roughness is determined by selecting operating parameters comprising a standoff distance (SD), a traverse velocity VTR of the nozzle, a water pressure P, a water flow rate Q, a length-to-diameter (L/d) ratio, the frequency f, and an amplitude A of the signal.

Abstract: Plume shield shroud (10) for a plasma gun (30) includes a substantially tubular member (14) comprising an axial length, a plume entry end (11), and a plume exit end (13). The shroud (10) is adapted to be mounted to a plasma gun (30).

Abstract: Shaping the feed wire for a combustion wire thermal spray process improves the operating capability of the combustion wire gun through higher feed rates and high operating efficiencies. The efficiency of the wire melting is increased over conventional systems through increasing the surface area of the wire cross section and exposing more of the wire material directly to the burner jets.

Abstract: Method for performing a thermal spray process. Method includes heating and/or accelerating a gas to form an effluent gas stream, feeding a particulate-bearing carrier stream through an axial injection port into the effluent gas stream to form a mixed stream, in which the axial injection port includes a plurality of chevrons located at a distal end of said axial injection port, and impacting the mixed stream on a substrate to form a coating.

Abstract: Method for performing a thermal spray process. Method includes heating and/or accelerating a gas to form an effluent gas stream, feeding a particulate-bearing carrier stream through an axial injection port into the effluent gas stream to form a mixed stream, in which the axial injection port includes a plurality of chevrons located at a distal end of said axial injection port, and impacting the mixed stream on a substrate to form a coating.

Abstract: A two stage kinetic energy spray device has a first stage first nozzle having a receiving end that receives a particulate stream, an injection end located axially to the first nozzle receiving end, the injection end receiving the particulate stream from the receiving end. A second stage has a second nozzle, the second nozzle having a gas receiving portion that receives an effluent gas, a convergent portion that is downstream from the gas receiving portion and a divergent portion that is downstream from the convergent portion, the convergent portion and the divergent portion meeting at a throat. The particle stream is accelerated to a first velocity in the first nozzle located within the second nozzle divergent portion The effluent gas is accelerated to a second velocity in the second nozzle. First nozzle injection end chevrons allow mixing of particulate and supersonic effluent streams prior to exiting the spray device.

Abstract: Powder injection apparatus, plasma gun, and method of use. Powder injection apparatus includes a shroud attachable to an outlet nozzle of a thermal spray apparatus and a substantially smooth and continuous inner wall defining a bowl through which a plume of the thermal spray apparatus travels. At least one port in the inner wall is structured and arranged to receive a powder injection nozzle that injects powder into the plume.

Abstract: An improved thermal spray apparatus and method of promotes mixing of axially fed particles in a carrier stream with a heated effluent stream without introducing significant turbulence into either the effluent or carrier streams. An axial injection port includes a plurality of chevrons at the distal end of the port. The chevrons are located radially around the circumference of the distal end of the axial injection port to increase the shared area between the two flow streams at the outlet of the port.

Abstract: The present invention provides a standard interface for providing mechanical location, mechanical orientation, electrical connections, and water chamber seals for the exchange of a variety of plasma forming nozzles each associated with a specific plasma plume characteristic. The flexibility of the nozzle attachment is improved over prior designs by providing a standard exterior nozzle configuration and nozzle clamping assembly on the plasma gun so that multiple nozzles configurations (giving different plasma flow properties) can easily be used with the same devices. The joining of the nozzle to the receptacle forms a channel for cooling liquid to flow from the plasma gun through the nozzle to a return path in the plasma gun and creates an electrical contact between the plasma gun and the nozzle.

Abstract: The present invention provides a method and apparatus of producing a dense coating with desirable stress conditions similar to coatings produced by a cold spray processes, but with higher process efficiencies and lower gas consumption. The inventive process combines features of a plasma process method of gas heating and a cold spray process to accelerate the gas, incorporating these elements into a single hybrid process.

Abstract: An improved thermal spray apparatus and method of promotes mixing of axially fed particles in a carrier stream with a heated effluent stream without introducing significant turbulence into either the effluent or carrier streams. An axial injection port includes a plurality of chevrons at the distal end of the port. The chevrons are located radially around the circumference of the distal end of the axial injection port to increase the shared area between the two flow streams at the outlet of the port.

Abstract: Shaping the feed wire for a combustion wire thermal spray process improves the operating capability of the combustion wire gun through higher feed rates and high operating efficiencies. The efficiency of the wire melting is increased over conventional systems through increasing the surface area of the wire cross section and exposing more of the wire material directly to the burner jets.