Abstract: A fuel nozzle is provided. The fuel nozzle includes a heat shield, a fuel tube and a plurality of support members. The support members are radially interposed between the heat shield and the fuel tube. The support members are preferably cylindrical tubes, thus creating voids or pockets between the heat shield and the fuel tube. The cylindrical tubes are connected to one another at a first end are free at an opposed end. As such, the tubes can move or slide relative to one another. Further, the tubes preferably only contact one another with at most line contacts. The fuel nozzle may also include a tip portion that includes a tip heat shield that extends radially outward from the primary heat shield. The tip heat shield defines a cavity that connects with the central cavity of the heat shield. The fuel tube extends through the tip heat shield.

Abstract: Various fuel injection systems and fuel injectors are disclosed that provide varying cooling rates for fuel injectors connected in series to fuel supply and drain rail. The local cooling rate for each injector is manipulated to balance the heat flux or heat transfer across the injectors disposed along the rail. The cooling rates may be manipulated by varying sizes of openings or slots in the nozzle case, by varying annular spaces disposed between the nozzle case and the portion of the injector body that houses the actuator and solenoid assembly, and by varying the size of annular spaces disposed between the nozzle case and the cylinder head. Strategic placement of slots in the nozzle case that direct more flow at the portion of the injector body that houses the actuator and solenoid assembly may also be employed. As a result, the operating temperatures of fuel injectors connected in series to a fuel rail can be manipulated and moderated so the downstream injectors are not prone to overheating.

Abstract: A fuel injector for a common rail fuel system includes a common rail inlet port fluidly connected to a high pressure common rail, and a cooling inlet fluidly connected to an output from a lower pressure fuel transfer pump. The cooling fluid circulates internally through the fuel injector to cool a single pole solenoid via both internal and peripheral cooling passages. In order to accommodate a small spatial envelope while providing superior performance, a thin insulating layer may separate the solenoid coil winding from an inner pole piece, and small flux gap clearances may permit a flux carrying portion of the injector body to be a portion of the single pole solenoid assembly.

Abstract: An internal combustion engine, such as a direct injection compression ignition diesel engine, includes an engine housing having a plurality of cylinders and a plurality of fuel injectors associated one with each of the cylinders. The fuel injectors each include a first fuel inlet and a second fuel inlet, and an actuator subassembly which is configured to actuate a control valve assembly positioned within the fuel injector. The engine further includes a fuel system having a fuel supply circuit, and a cooling system for the actuator subassembly having a cooling circuit with a segment in common with a segment of the fuel system. The cooling system is configured to pass cooling fuel across a heat exchange interface of the actuator subassembly to exchange heat therewith. The actuator subassembly may include a piezoelectric actuator and a preloading spring, which are each fluidly sealed within a casing of the actuator subassembly.

Abstract: A regeneration device for use in an exhaust treatment system is disclosed. The regeneration device has a first housing with a plurality of passages configured to receive coolant and injection fluid. A second housing is secured to the first housing and configured to receive coolant and injection fluid. The second housing has at least one cooling recess annularly disposed within the second housing to receive and circulate coolant in proximity to a tip end of the second housing.

Abstract: Methods and apparatus for injecting reagent, such as an aqueous urea solution, into an exhaust stream in order to reduce emissions from an engine exhaust. The present teachings can use a whirl plate having a plurality of whirl slots surrounding an exit orifice of an injector, which produce a high velocity rotating flow in the whirl chamber. When the rotating flow of reagent is passed through the exit orifice into an exhaust stream, atomization occurs from a combination of centrifugal force and shearing of the reagent by air as it jets into the exhaust stream.

Abstract: The straw designed for the intake of water based drink from a container. In the lower part of the flexible straw there are holes that are connected to the main tube of the straw. Above the holes and attached to the straw, there is a floating device which allows for the intake of the drink from the container only from fixed depth ranges, preferably from 5-15 mm from the surface of the water. The straw allows for the protection of the organism of the user from negative effects of the drink on the body's cells.

Abstract: A fuel injector for a gas turbine engine of an aircraft, and more particularly a novel and unique heatshield structure for a fuel nozzle wherein a labyrinth seal is uniquely provided in the nozzle to isolate a portion of an insulating gap from an interface whereat fuel may enter the insulating gap, and the insulating gap is provided with a positive purge flow for forcing vapors out of the insulating gap.

Abstract: Apparatus and methods for the dispersion of material into a drying gas stream are disclosed. The material dispersion apparatus can have a nozzle and a venturi positioned downstream of the nozzle. The drying gas stream can be generated by pulse combustion dryer or by spray dryer and pass over at least a portion of the nozzle.

Abstract: An injector for an injection system is provided, including a first opening, a second opening, an open position and a closed position. The first opening is for spraying the fluid out of the injector, and the second opening is for allowing the fluid to exit the injector. When the injector is in the open position, the injector sprays the fluid from the first opening and the flow of the fluid to the second opening is substantially blocked. When the injector is in the closed position the injector allows the fluid to exit the injector from the second opening. The injector substantially blocks the spray of the fluid from the first opening when the injector is in the closed position.

Abstract: Disclosed is a fuel injection nozzle comprising a cooling duct (6) that is disposed in the final region of a housing (1), which faces the combustion chamber. In order to cool the zones that are subjected to high thermal stress, the cooling duct (6) is positioned closer to the bore (2) of the valve needle than to the external face of the housing (1) and is provided with a cross-sectional area that has a width corresponding to no more than the height which extends in the axial direction of the nozzle.

Abstract: An oxygen blowing lance for steel production, the lance having a protection element. The end of a main oxygen tube at the lance head has a cover shell with outlets. An oxygen outlet nozzle is removably and exchangeably fastened to each outlet. The protection element is provided removably and exchangeably at the lance head end of the oxygen blowing lance. An intermediate space is present between the lance head end of the oxygen blowing lance and the protection element. Penetrations are provided in the protection element, the oxygen outlet nozzles passing through the penetrations from the shell outward, and a gap remains between the oxygen outlet nozzle and the protection element. A protective gas line feeds into the intermediate space between the lance head end of the oxygen blowing lance and the protection element. A method for operating the oxygen blowing lance is also described.

Abstract: A plasma spray nozzle is provided. Owing to their high degree of wear, previous plasma spray nozzles were not suitable for the coating of components for which long coating times were necessary. The coating times may be reduced considerably by the triple injection of powder into the inner channel through the plasma spray nozzle.

Abstract: An injection nozzle having a main body portion with an outer peripheral wall is disclosed. The nozzle includes a plurality of fuel/air mixing tubes disposed within the main body portion and a fuel flow passage fluidly connected to the plurality of fuel/air mixing tubes. Fuel and air are partially premixed inside the plurality of the tubes. A second body portion, having an outer peripheral wall extending between a first end and an opposite second end, is connected to the main body portion. The partially premixed fuel and air mixture from the first body portion gets further mixed inside the second body portion. The second body portion converges from the first end toward said second end. The second body portion also includes cooling passages that extend along all the walls around the second body to provide thermal damage resistance for occasional flame flash back into the second body.

Abstract: A method of reducing emissions from a diesel engine including the steps of providing an injector to an exhaust outlet of the diesel engine, the injector having an orifice with a diameter of about 0.006 inch or less, providing a reagent to the injector at an inlet pressure between about 120 psi and about 60 psi, actuating the injector on and off at a frequency between about 10 Hz and about 1 Hz with an on-time of about 1% or more, injecting the reagent via the orifice into the exhaust outlet at an injection rate, and wherein varying of at least two of the inlet pressure, the frequency, and the on-time achieves a turn-down ratio of a maximum injection rate to a minimum injection rate of at least about 31:1.

Abstract: An SCR-injection unit includes an injector, a sleeve element for fixing the injector to a flange of an exhaust gas pipe, and a cooling body. According to the invention, the sleeve element has an elongated thin-walled connecting section, one axial end of which is indirectly connected to the flange of the exhaust gas pipe and the other axial end of which is indirectly connected to a supporting structure for the injector.

Abstract: A thermal load control assembly for a fuel injector includes a rail inlet port, a cooling inlet port and a fuel drain port. A leakage path channels leaked fuel originating from the rail inlet port to the fuel drain port. A cooling path channels fuel originating from the cooling inlet port to the fuel drain port. A fuel system using a thermal load control assembly includes a single fuel tank that supplies fuel to the rail inlet port and the cooling inlet port of a plurality of fuel injectors and collect fuel from the fuel drain port of the plurality of fuel injectors.

Abstract: A fuel injector includes an injector body forming an actuator portion. An actuator bore is formed in the actuator portion and is at least partially defined by an inner surface and by an end surface. An actuator disposed in the actuator bore and has an outer surface such that a flow channel can be defined between the inner surface of the actuator bore and the outer surface of the actuator. A cooling flow passage is formed in the injector body, in fluid communication with the actuator bore, and is adapted to supply cooling fluid to the actuator bore. A drain passage is formed in the injector body, in fluid communication with the actuator bore. An internal cooling fluid flow path extends from the cooling flow passage, through the flow channel, and from the flow channel through the drain passage.

Abstract: A system that includes a turbine fuel nozzle comprising an air-fuel premixer. The air-fuel premixed includes a swirl vane configured to swirl fuel and air in a downstream direction, wherein the swirl vane comprises an internal coolant path from a downstream end portion in an upstream direction through a substantial length of the swirl vane.

Abstract: A fuel injection nozzle comprises a body member having an upstream wall opposing a downstream wall, a baffle member having an upstream surface and a downstream surface, a first chamber, a second chamber, a fuel inlet communicative with the first chamber operative to emit a first gas into the first chamber, and a plurality of mixing tubes, each of the mixing tubes having a tube inner surface, a tube outer surface, a first inlet communicative with an aperture in the upstream wall operative to receive a second gas, a second inlet communicative with the tube outer surface and the tube inner surface operative to translate the first gas into the mixing tube, a mixing portion operative to mix the first gas and the second gas, and an outlet communicative with an aperture in the downstream wall operative to emit the mixed first and second gasses.

Abstract: A heated fuel injector includes a fuel inlet for receiving fuel, a fuel outlet for dispensing fuel from the heated fuel injector, and a heated body having an inside surface fore fluidly connecting the fuel inlet to the fuel outlet. The heated fuel injector also includes a hollow pintle shaft that is reciprocably movable within the heated body for selectively permitting and preventing the dispensing of fuel from the fuel outlet. A fuel passage is formed between the inside surface and the hollow pintle shaft such that fuel flows through the passage from the fuel inlet to the fuel outlet. The hollow pintle shaft defines a sealed chamber within the hollow pintle shaft which thereby increases the efficiency by which the heated body can heat the fuel flowing through the fuel passage.

Abstract: In a snow lance head for use with a snow lance with a housing having nozzles for the outlet of water and/or air and with at least one first chamber formed in the interior of the housing, through which water emerging from at least some of the nozzles flows, the surface area of the inner surface of the chamber is at least equal to, but preferably greater than the outer surface of the housing.

Abstract: A pilot nozzle heat shield includes a body having a first end for receiving a pilot nozzle and a second end including a flow tip. The body includes a plurality of internal turbulators circumferentially disposed about the internal peripheral surface of the body. The flow tip includes a proximal periphery and a distal periphery. A plurality of flow ports are circumferentially spaced about the proximal periphery of the flow tip. The flow tip includes a plurality of slots. Each slot extends distally from one of the flow ports to the distal periphery of the flow tip, which defines an aperture. The plurality of slots define a plurality of tangs; each tang is defined between a pair of neighboring slots. A plurality of turbulators can be disposed about the inner peripheral surface of the heat shield body at the tangs.

Abstract: A method and apparatus for a diffusion tip for use with a fuel nozzle is described. The diffusion tip has a substantially circular body including an outer surface and an opposite inner surface. The diffusion tip body extends from a discharge end to an inlet end. The diffusion tip includes an inlet surface adjacent to the discharge end and defined within the body. A discharge surface is defined opposite the inlet surface. A plurality of diffusion apertures each extend between the discharge surface and the inlet surface, each aperture is oriented relative to the body to discharge a diffusion flow outward therefrom at an angle ? (gamma) measured in an X-Z plane between a centerline of the aperture and an X-axis extending tangentially to the outer surface, and at an angle ? (theta) measured in a Y-Z plane between the centerline of the aperture and a Y-axis extending radially outward from the centerline.

Abstract: The present invention provides an improved combustion head and combustion chamber for use with known flame spray apparatus. The combustion head includes a body portion defining a combustion opening for receiving an outlet end of the combustion chamber and an interior chamber extending from the combustion opening into the body portion. The body portion also defines a material feed conduit extending through the body portion along a longitudinal axis thereof. The body portion being substantially hollow wherein the interior chamber extends from the combustion opening throughout substantially the entire body portion including adjacent the material feed conduit. The body portion defining coolant channels on an outer surface thereof of varying depth such that the wall thickness of the body portion at the coolant channels is substantially uniform. The combustion chamber having a flange formed on an outer surface thereof for limiting insertion of the combustion chamber into the combustion head.

Abstract: Clogging of an injection nozzle which supplies a reducing agent to the exhaust gas on an upstream side of a reduction catalyst in the exhaust gas passage is prevented, and the efficiency of NOx purification processing is improved. A reducing agent supply unit uses a detection signal of the exhaust gas temperature from a temperature detection device to set a supply quantity at or above a lower limit for cooling the interior of an injection nozzle to below the temperature at which urea water crystallizes, for the detected exhaust gas temperature, and supplies urea water to the injection nozzle at the set supply quantity. By such supply of urea water, the interior of the injection nozzle is cooled to below the temperature at which the urea water crystallizes. As a result, the urea water does not crystallize inside the injection nozzle, and clogging of the injection nozzle can be prevented.

Abstract: A thermal load control assembly for a fuel injector includes a rail inlet port, a cooling inlet port and a fuel drain port. A leakage path channels leaked fuel originating from the rail inlet port to the fuel drain port. A cooling path channels fuel originating from the cooling inlet port to the fuel drain port. A fuel system using a thermal load control assembly includes a single fuel tank that supplies fuel to the rail inlet port and the cooling inlet port of a plurality of fuel injectors and collect fuel from the fuel drain port of the plurality of fuel injectors.

Abstract: A high speed valve has a conductive flyer plate responsive to eddy currents induced by an adjacent coil. The eddy currents generate a repulsive force which opens the valve, and a low-mass flyer plate and spring combined with a resonant plate and spring combination provide a fast opening and closing time for the valve. A nozzle structure directs a supersonic flow of gas into a rectangular array of high-density gas suitable for interaction with a laser beam transverse to the rectangular array of jets for the production of wakefield interaction, leading to very high-energy electrons from the gas jet.

Abstract: A fuel injector having a fuel heater and an insulating air jacket. The fuel injector includes a fuel heater disposed on the outside of the injector body. The injector body conducts heat energy from the heater element to the fuel chamber preferably via cooling fins that protrude into the fuel path. The heater and injector body are disposed within a closed air jacket formed with the shell of the injector. As air has low thermal conductivity, this feature directs most of the heat energy radially inward through the wall of the injector body into the fuel. The injector is especially useful in injecting low-volatility fuels into internal combustion engines under low-temperature conditions.

Abstract: A fuel nozzle for delivery of fuel to a gas turbine engine. The fuel nozzle includes an outer nozzle wall and a center body located centrally within the nozzle wall. A gap is defined between an inner wall surface of the nozzle wall and an outer body surface of the center body for providing fuel flow in a longitudinal direction from an inlet end to an outlet end of the fuel nozzle. A turbulating feature is defined on at least one of the central body and the inner wall for causing at least a portion of the fuel flow in the gap to flow transverse to the longitudinal direction. The gap is effective to provide a substantially uniform temperature distribution along the nozzle wall in the circumferential direction.

Abstract: A fuel injector is provided. The fuel injector includes a nozzle, a cooling assembly, and a tip coupled to the nozzle. The tip includes a base including a cooling channel defined therein, a first transition member extending outwardly from the base and in flow communication with the cooling channel, and a second transition member extending outwardly from the base and in flow communication with the cooling channel, wherein the base, the first transition member, and the second transition member are formed integrally together. The tip is configured to couple to the cooling assembly to channel a flow of cooling fluid through the cooling channel via the first transition member and the second transition member.

Abstract: A fuel injector including a nozzle portion, a solenoid operated valve assembly configured to control a flow of fuel to the nozzle portion, a housing, at least a portion of the solenoid operated valve assembly disposed in the housing, the housing formed of a first material having a first thermal conductivity value, and a heat transfer element associated with the solenoid operated valve assembly, the heat transfer element attached to the housing, the heat transfer element formed of a second material having a second thermal conductivity value, the second thermal conductivity value being greater than the first thermal conductivity value.

Abstract: A heated fuel injector includes a heated body, liquid fuel flowing through a fuel passage within the body, and a member that increases heat transfer from the heated body to the fuel within the fuel passage. The thermal efficiency of the fuel injector is increased separately or in combination by diverting the fuel flow along an inner circumferential contour of the heated body, by limiting the volume of fuel bypassing the heated inner surface of the body, by redirecting heat from the body to unheated portions of the fuel flow field within the fuel passage, and by increasing the available contact surface area for heat transfer. Improved heat transfer from the heated body to the fuel is achieved by integrating features that increase the contact surface area into the inside surface of the body or by positioning an insulating or a thermally conductive spacer within the fuel passage.

Abstract: The present invention relates to an exhaust system for an internal combustion engine, in particular in a motor vehicle, having an exhaust line carrying exhaust gas away from the internal combustion engine and having a fuel injector for injecting fuel into the exhaust line. The fuel injector is mounted on the exhaust line via a mounting device. This mounting device has a receiving body into which the fuel injector is inserted and which is mounted on the exhaust line via a disk-shaped flange. To reduce the risk of overheating of the fuel injector, the flange is mounted on the receiving body via a constriction in cross section and/or on the exhaust line via a thermal insulator.

Abstract: A fuel distributor is disclosed comprising a body having a unitary construction, a fuel conduit located within the body, a fuel flow path located within the body that is oriented in a circumferential direction around an axis and in flow communication with the fuel conduit, and at least one orifice located in the body in flow communication with the fuel flow path such that a fuel entering the fuel conduit exits through the orifice.

Abstract: A system for injecting from an injector into a duct of an engine system is provided. The system may include a first flange on a duct connection side, a second flange on an injector connection side, a stand-off separating the first flange from the second flange to form an air gap therebetween, and a seal offset from at least one of the first and the second flanges and located within the airgap and between the first flange and the second flange.

Abstract: The invention relates to an apparatus for thermal spraying (1) including a spray gun (2) with a burner (3), wherein an operating media (5) can be supplied to the spray gun (2) via a feed line (4), and a base part (6) which is in communication with a supply unit (8) for the operating medium (5) via a supply line (7). A releasable coupling device (9) is provided, with the feed line (4) including an adapter part (10) such that the adapter part (10) can be connected to the base part (6) by means of the releasable coupling device (9).

Abstract: An injection molded nozzle includes a base body having a fluid channel, a fluid inlet, and a fluid outlet. The base body is made of a ceramic material with a positive temperature coefficient. The base body, in response to an electrical current, is configured to vaporize a fluid receivable in the fluid channel by heating. The fluid outlet is configured to eject vaporized fluid as a spray.

Abstract: A method of manufacturing a variety of injection molding hot runner system components using two materials. Blanks for portions of the components are formed of each material and fused, preferably by electron beam welding, then the component having the two portions is machined to its final configuration. Components made with this process include nozzle tip components such as tips, tip retainers, and tip inserts, as well as manifold bushings, valve stems and nozzle housings.

Abstract: A direct injection spark ignition internal combustion engine includes a fuel injector for directly injecting fuel into a cylinder and intensifies a tumble flow using the fuel injected into the cylinder bore at a time near an intake stroke bottom dead center during homogenous combustion. The thrust force of the fuel injected from the fuel injector is set to intensify the tumble flow based on at least one of the state of the combustion chamber, the temperature of the injected fuel, and the orientation of the injection hole.

Abstract: A fuel injector for a gas turbine engine of an aircraft, and more particularly a novel and unique heatshield structure for a fuel nozzle wherein a labyrinth seal is uniquely provided in the nozzle to isolate a portion of an insulating gap from an interface whereat fuel may enter the insulating gap, and the insulating gap is provided with a positive purge flow for forcing vapors out of the insulating gap.

Abstract: A fuel injector for heating fuel to be injected into an internal combustion engine. A cylindrical barrel extends between a solenoid and an injection tip for passage of fuel. The outer surface of the barrel supports a suitable circuit pattern formed of an electrically resistive material for generating heat which is passed through the wall of the barrel to warm the fuel which may be stationary or flowing. The electrically resistive material has a positive thermal coefficient, permitting voltage to be applied continuously across the heater causing a current to flow through the heater, the current being inversely proportional to the temperature of the heater. Thus, the heater is self-regulating, the current automatically increasing under cold conditions and diminishing as the fuel injector warms up after starting of the engine. Desirably, the heater is outside both the engine firing chamber and the flow path of the fuel.

Abstract: A bi-propellant rocket engine may include a primary propellant flowing in a central passageway, a secondary propellant flowing in a secondary passageway generally coaxial with central passageway and a pintle tip having a central chamber sidewall coaxial with the primary passageway and surrounding a central chamber, the central chamber sidewall having a first plurality of apertures there through so that some of the primary propellant exits the central chamber transverse to the flow of the secondary propellant in the secondary passageway. The pintle tip may have a secondary chamber sidewall, substantially thicker than the primary chamber sidewall, surrounding a secondary chamber downstream of and in fluid communication with the primary chamber, the secondary chamber sidewall having a second plurality of apertures there through so that some of the primary propellant exits the secondary chamber transverse to the flow of the secondary propellant in the secondary passageway.

Abstract: The present invention provides methods and apparatus for injecting reagent, such as an aqueous urea solution, into an exhaust stream in order to reduce oxides of nitrogen (NOx) emissions from diesel engine exhaust The present invention uses mechanical spill return atomization techniques to produce droplets approximately 50 ?m SMD (Sauter mean diameter) or smaller. This size range is appropriate to allow urea to react into ammonia within the residence time associated with an on-road diesel engine. This effect is achieved through the use of a whirl plate having a plurality of whirl slots surrounding an exit orifice of the injector, which produce a high velocity rotating flow in the whirl chamber. When the rotating flow of reagent is passed through the exit orifice into an exhaust stream, atomization occurs from a combination of centrifugal force and shearing of the reagent by air as it jets into the exhaust stream.

Abstract: A method of manufacturing a variety of injection molding hot runner system components using two materials. Blanks for portions of the components are formed of each material and fused, preferably by electron beam welding, then the component having the two portions is machined to its final configuration. Components made with this process include nozzle tip components such as tips, tip retainers, and tip inserts, as well as manifold bushings, valve stems and nozzle housings.

Abstract: An actuated atomizer is adapted for spray cooling or other applications wherein a well-developed, homogeneous and generally conical spray mist is required. The actuated atomizer includes an outer shell formed by an inner ring; an outer ring; an actuator insert and a cap. A nozzle framework is positioned within the actuator insert. A base of the nozzle framework defines swirl inlets, a swirl chamber and a swirl chamber. A nozzle insert defines a center inlet and feed ports. A spool is positioned within the coil housing, and carries the coil windings having a number of turns calculated to result in a magnetic field of sufficient strength to overcome the bias of the spring. A plunger moves in response to the magnetic field of the windings. A stop prevents the pintle from being withdrawn excessively. A pintle, positioned by the plunger, moves between first and second positions.

Abstract: An injection nozzle for use in delivering fuel to a combustion space, the injection nozzle comprising a nozzle body, at least a part of which is provided with a first coating arranged so as to reduce the temperature of at least a part of the nozzle body, in use. The coating may have either a higher or lower thermal conductivity than the thermal conductivity of the nozzle body.

Abstract: A pilot nozzle heat shield includes a generally cylindrical body having a first end for receiving a pilot nozzle. The body includes a plurality of radial retention pin cavities for receiving retention pins. A frustoconical flow tip is located at a second end of the body that includes a proximal periphery and a distal periphery. A plurality of flow jets are circumferentially spaced about the proximal periphery of the frustoconical flow tip which further includes a plurality of slots extending distally from the plurality of flow jets. The plurality of slots define a plurality of tangs and the plurality of tangs define an aperture at the distal periphery of the flow tip. At least two of the tangs are connected about the distal periphery of the flow tip and the pilot nozzle heat shield generally includes at least two sets of connected tangs.

Abstract: Small crystals are made by mixing a solution of a desired substance with an anti-solvent in a fluidic vortex mixer in which the residence time is less than 1s, for example 10 ms. The liquid within the fluidic vortex mixer (12) is subjected to high intensity ultrasound from a transducer (20, 22). The solution very rapidly becomes supersaturated, and the ultrasound can induce a very large number of nuclei for crystal growth. Small crystals, for example less than 5 ?m, are formed. The resulting suspension is treated so as to add or remove ingredients, and then spray dried using an atomizer tuned to create small droplets in such a way that each droplet should contain not more than one crystal. Crystal agglomeration is hence prevented.

Abstract: The present invention discloses a thermal spray apparatus with improved thermal efficiency and wear resistance in both the nozzle and barrel combustion chamber. Specifically, disclosed herein is a thermal spray apparatus for spraying substrate coatings, comprising a high velocity oxygen fuel (HVOF) gun wherein said gun includes a combustion chamber generating heated flow therefrom and a nozzle downstream from said chamber. The nozzle and/or chamber contain a first layer of material heated by the flow, and a second layer of material which contacts the first layer when said first layer is heated. The first layer has a thermal conductivity that is lower than said second layer and preferably a lower thermal expansion coefficient. In use, the contact of the first heated layer of material with the second layer operates to remove heat from the first layer therein providing automatic/self-regulating temperature control of the HVOF apparatus.