Abstract: A coating system includes a support fixture sized to be partially inserted into one or more openings of a component and a spray nozzle segment device comprising a housing configured to receive a slurry. The device is disposed radially outward of a central axis of the component and is shaped to extend circumferentially about at least part of the central axis of the component. The housing comprises plural delivery nozzles configured to spray the slurry onto a surface of the component. The device is operably coupled with the support fixture such that the fixture maintains a position of the device within the component when the support fixture is partially inserted into one or more openings of the component.

Abstract: A nozzle for additive manufacturing includes a plasma gas tube operable to provide plasma gas to a plasma flame, and a source material tube arranged concentrically inside the plasma gas tube such that the source material passes through the plasma flame. An apparatus and method for additive manufacturing are also disclosed.

Abstract: A nozzle for additive manufacturing includes a plasma gas tube operable to provide plasma gas to a plasma flame, and a source material tube arranged concentrically inside the plasma gas tube such that the source material passes through the plasma flame. An apparatus and method for additive manufacturing are also disclosed.

Abstract: A wire arc spray system use at least one first wire and second wire that include a composite wire including a first material at a core region thereof and a cladding including a second material surrounding the core region. A controller controls operation to propel heated material created by the arcing of the first wire and the second wire at the arc point to a surface to be coated. A wire arc spray methodology for creating a porous metal coating with all-metal wires is also provided.

Abstract: A torch introduces oxidizer into a passage so as to swirl the oxidizer about a central axis, while fuel is introduced at a location spaced apart from the central axis, where the swirling action of the oxidizer is strong, resulting in rapid mixing of the fuel and oxidizer. In practicing the method, the length of a bore through which the fuel and oxidizer pass is maintained short enough that a sheath of unmixed oxidizer surrounds the combusting mixed fuel and oxidizer, eliminating any need for water cooling. The lengths of torches of the present invention can be significantly shorter than those of the prior art, making the torches well suited for use in confined spaces, and the torches have been found to allow spraying materials at a greater rate than torches of the prior art. The reduced length also facilitates introducing into the passage material to be spray-coated.

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: The invention relates to a thermal spraying apparatus (1) for coating a surface (2) of a substrate (3) by means of a coating material (4). The thermal spraying apparatus (1) includes a spray pistol (5) with a heating device for heating the coating material (4) in a heating zone (6) and also a charging apparatus (7) with a feed (8) through which the coating material (4) can be introduced into the heating zone (6). In this arrangement the thermal spraying apparatus is so designed that a relative position (9) between the feed (8) and the heating zone (6) can be changed in the operating state.

Abstract: A powder port blow-off system for a plasma spray process includes a faceplate that includes a bore therein that is co-radially aligned with a nozzle of a plasma spray gun, which emits a plasma plume. A plurality of powder feed ports are arranged circumferentially around the nozzle for injecting a flow of powder particles toward the plasma plume. A plurality of powder port blow-offs are arranged circumferentially around the nozzle in order to direct blow-off gas across the powder feed ports. The powder port blow-offs are directed across the plasma plume to create a vortex for carrying away powder particles unconsumed by the plasma plume.

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: An electric arc spraying system includes a spraying gun for thermally spraying an inner surface of an object such as a cylinder block by blasting compressed gas substantially perpendicularly to the supplying direction of target wires. The spraying gun is rotated by a spraying gun rotation mechanism. The target wires are loaded in and supplied from wire supplying sources. A wire feeder rotation mechanism is provided for rotating the wire supplying sources synchronously with the spraying gun in rotation. Wire feeders are provided at the spraying gun or adjacent to the wire supplying sources for feeding the target wires. Wire support cables are configured to guide the target wires from the wire supplying sources to the spraying gun.

Abstract: The invention relates to an electric arc wire burner for spraying an electric arc, comprising at least two burner tubes (3) for feeding electrodes which are embodied in the form of wire (5). Said electrodes are guided through the burner tube (3) in the direction of the surface of the object which is to be coated. The wire (5) is guided by a deflection device (7) comprising a number of rotationally mounted guiding elements and/or sliding elements (8) and the wire (5) is deformed in an elastic area.

Abstract: A microprocessor controlled arc metalizing unit includes a wire cassette and a drive mechanism cassette engaged in a separable manner. By disengaging the wire cassette and drive mechanism cassette, an operator has much greater control of the unit since the wire loaded wire cassette is fixed and the operator need only maneuver the lightweight drive mechanism cassette. To improve the safety of the arc metalizing unit, a “dead-man” switch acts to automatically shut down the arc metalizing unit should any number of preestablished safety conditions be breached. In addition, one or more composite housings enclose the operational components of the arc metalizing unit to improve safety. Reliability is improved through a tension control unit that eliminates any rotational fluctuations associated with wire spools. The arc metalizing unit further incorporates a touch pad control with a display for operating the unit and displaying the status of the unit.

Abstract: In a thermal spray process, a wire is fed into a flame-jet to heat said wire to the melting point, atomize and projected high velocity the droplets so formed against a surface to buildup a coating of material on the surface. The wire is fed into the flame by aligning the cast-plane of the wire with the flame-jet by using a tubular member formed into a circular shape to provide sufficient length to guide wire and to provide the necessary twist amount to the wire to align the cast-plane with the axis of the flame-jet.

Abstract: A nozzle assembly for a HVOF thermal metallic spray coating system includes an inner tube, a middle tube and an outer tube which are concentrically arranged about an axis of the nozzle assembly and are spaced to provide annular, concentric gas flow passages for oxygen and gaseous fuel along with a central wire feed passage in an efficient, compact arrangement. A slotted nib and plug are fitted to the discharge end at the assembly and defined, together with the middle tube, an annular premix chamber for the combustible gases, and a plurality of circumferentially spaced mixing slots and a downstream mix end portion of the nib where complete mixing of the gases occurs prior to entry into the combustion chamber provided in an air cap. An annular passage between the air cap and outer tube communicates with a high pressure air source for establishing an envelope of air against the inside surface of the air cap to serve as a protective barrier layer from the atomized metal.

Abstract: An arc spray gun has a pair of wire guides that guide two metal wires to an arc zone near the wire tips where an electric current through the wires effect an arc, thereby melting the wire tips. The wire guides are of a two-part design. One part is easily removable without the need for tools. Generally, each removable part of the wire guide is temporarily held within a stationary wire guide by an O-ring. A retainer then holds the removable wire guide firmly in place. A gas cap keeps the retainer firmly against the removable wire guides while the gun is in use.

Abstract: A nozzle assembly for a HVOF thermal metallic spray coating system includes an inner tube, a middle tube and an outer tube which are concentrically arranged about an axis of the nozzle assembly and are spaced to provide annular, concentric gas flow passages for oxygen and gaseous fuel along with a central wire feed passage in an efficient, compact arrangement. A slided nib and plug are fitted to the discharge end at the assembly and defined, together with the middle tube, an annular premix chamber for the combustible gases, and a plurality of circumferentially spaced mixing slots and a downstream mix end portion of the nib where complete mixing of the gases occurs prior to entry into the combustion chamber provided in an air cap. An annular passage between the air cap and outer tube communicates with a high pressure air source for establishing an envelope of air against the inside surface of the air cap to serve as a protective barrier layer from the atomized metal.

Abstract: A thermal spray or welding apparatus including a cored wire electrode with a sheath and a multiplex powder composite. The composite comprises micron-sized particles and sub-micron sized particles, including nano-scale particles, the particles mechanically cooperating to promote smooth powder flow, which facilitates compaction of the cored wire electrode. The invention also includes a method of manufacture of the apparatus including the cored wire electrode and its method of use to deposit a low porosity coating with high levels of alloyed refractory elements that is adherent and low in oxide content.

Abstract: A flame spray system employs splatter blocking and automated rod delivery apparatuses. The splatter blocking apparatus includes a barrier member and an actuation mechanism. The barrier member is adapted to be moved between a blocking position in which the barrier member is extended across a spray path from a flame spray gun of a flame spray system preventing travel of particles of fusible material from the flame spray gun to a product being coated and an unblocking position in which the barrier member is displaced from the spray path of the flame spray gun permitting travel of particles fusible material from the flame spray gun to the product being coated. The actuation mechanism is connected to the barrier member and adapted to be selectively actuated to move the barrier member between the blocking and unblocking positions.

Abstract: In a two-wire arc spray extension two metal wires are guided into contact, and a gas cap is affixed to a gun body. The feeding wires receive an arc current to effect an arc and thereby molten metal at the wire tips. The gas cap has a plurality of orifices therein that receive pressurized gas to generate gas jets. The orifices are disposed with substantially equal spacing arcuately such that the jets are directed with a radially inward component toward the tips to effect atomization of the molten metal into a spray stream. The orifices have axes that are offset forwardly and tangentially from radial so as to create a vortex flow such that the spray stream is effected in the form of a conical fan. Insertion of the spray stream centrally into a hole can effect a coating circumferentially on an inside surface of the hole.

Abstract: An arc spray gun has a pair of tubular wire guides that guide two metal wires to a point of contact at the wire tips where an arc current through the wires effect an arc, thereby melting the tips. Primary gas channeling on a central axis issues a primary gas flow that atomizes the molten metal and effects a spray stream thereof. A gas cap has at least four orifices arcuately spaced equally about the central axis. The orifices direct secondary gas jets inwardly with a forward directional component toward a point of intersection of the orifice axes on the central axis. The point of intersection is located proximate the point of contact and spaced downstream therefrom sufficiently for the jets not to interfere substantially with the atomization. The spray stream thereby is constricted and accelerated by the secondary gas jets.

Abstract: A wire thermal spray gun such as a two-wire arc gun has a speed regulator for a DC pull motor in the gun. Armature current corresponds to pulling torque on the pull motor depending on load resistance of the wires. A DC push motor is between a wire supply and the gun, with wire conduits connecting to the gun. A controller provides the push motor with a controlled pushing torque. Feedback of the armature current of the pull motor to the controller adjusts the pushing torque in direct response to change in the pulling torque, such that load sharing is maintained between the push motor and the pull motor.

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: A control apparatus is coupled to a flame spray gun for controlling the rate of feeding of a rod of heat fusible material through the gun. The control apparatus includes an electric motor adapted to be drivingly coupled to a flame spray gun and being operable in response to application of a D.C. voltage thereto to generate rotary motion to produce and control feeding of a rod of heat fusible material through the flame spray gun, an A.C. to D.C. converter and regulator device for generating and applying the D.C. voltage to the electric motor, a manually adjustable potentiometer connected to the converter and regulator to vary the quantity of D.C.

Abstract: In an angular gas cap on a wire thermal spray gun, a forward channel extends from a rearward channel at an oblique angle thereto so as to have a lateral directional component. The rearward channel at the nozzle has a channel axis parallel to the central axis of the nozzle and is offset from the central axis in a direction opposite the lateral directional component. Immediately upon termination of spraying the wire is retracted into the nozzle. A wire positioner includes a hollow collet with the wire extending therethrough. A linear actuator retains the collet against a wall to hold the collet open from the wire during spraying. Upon termination of spraying the actuator retracts to release the collet from the wall so the collet is sprung to engage the wire during the retraction. Upon startup the wire is advanced into the gas cap faster than normal spraying speed.

Abstract: The invention relates to a wire pistol comprising a wire feed mechanism including a wire feed pulley rotated by a DC motor and a counterpulley for biasing the wire into engagement with the feed pulley. It is an object of the invention to provide a wire pistol of this type in which, in contrast to prior-art wire pistols, no transmission shift operation or no transmission replacement is required over the entire adjustment range of wire feed rates. This object is attained according to the invention by the provision that the DC motor is adapted to have successive operating voltage pulses of variable pulse width and/or variable pulse frequency applied thereto for thus controlling the wire feed rate. This provision ensures that a sufficiently high torque for the wire feed operation is also available at very low wire feed rates, i.e. at low rotational speeds of the motor.

Abstract: An apparatus for producing a solid aerosol, such as a carbon aerosol, in which aerosol particles are produced by spark discharge via particle-supplying electrodes and the particles are entrained by a gas flow. Electrodes having parallel, adjacent end faces and are prvided with a feed drive moving them synchronously in a direction toward one another.

Abstract: A powder or wire thermal spray gun, useful for spraying a low oxide coating of oxidizable material, comprises a nozzle member with a nozzle face, and a gas cap extending from the nozzle member and having an inwardly facing cylindrical wall defining a combustion chamber with an open end for propelling combustion products into the ambient atmosphere at supersonic velocity and an opposite end bounded by the nozzle face. An annular flow of a combustible mixture is injected from the nozzle member coaxially into the combustion chamber at a pressure therein sufficient to propel combustion products of the mixture from the open end at supersonic velocity. A first annular flow of inert gas is injected adjacent to the cylindrical wall radially outward of the annular flow of the combustible mixture.

Abstract: An electric arc spray metalizing apparatus includes a spray gun which delivers a metalizing coating to the substrate, and a wire feed drive mechanism which pushes wires to the spray gun through cables. The wire is pushed by a pair of drive contact rollers or devices which are connected in a tandem relationship and operatively contact each wire to individually impart driving or pushing force to the wire. The wires are directed at the spray gun to an intersection point where electrical energy creates an arc for consuming the ends of the wires at the intersection point. The wires are electrically charged by contact with a curved wire guide as the wires are bent when pushed through the wire guide. A flow stream of pressurized gas is directed onto the intersection point and the molten metal of the consumed wire ends is directed in a spray stream of molten metal particles. A pair of deflecting streams of pressurized gas influence the spray stream by deflecting it into an elliptical or elongated deposition pattern.

Abstract: The products of combustion of compressed air and fuel fed to an internal burner issue through one or more orifices into a single large diameter expansion or nozzle bore open to the atmosphere. Solid rod or solid particle material to be sprayed is passed concurrent with the products of combustion through the large diameter chamber with the material being heat softened or melted to form a spray which is impacted against a workpiece after acceleration to high velocity. The pressure within the large diameter chamber is maintained sub-atmospheric. By aspirating atmospheric air flow bearing particulate material or by leaking air about a solid rod to the sub-atmospheric chamber pressure, pre-melting of the wire or particulate material within the material feed passage upstream of the chamber and prevented via hot combustion product gas back flow.

Abstract: A metal spray gun of the arc spray type has a nozzle-positioner member of electrically insulating material that is disposed between a gas inlet and an arc zone. A primary stream of gas is flowed through a through passage in the nozzle-positioner member, and seat surfaces in the through passage receive tips of individual electrically conductive contact tube assemblies that are biased outwardly away from one another. The nozzle-positioner member aligns the contact tube assemblies and configures the gas stream such that each metal wire is immediately enveloped in gas flow as it emerges from its contact tube and remains in that enveloping gas flow throughout the region between the contact tube tip and the arc zone. The spray gun produces quality metal spray coatings with lower gas pressures and has lower noise levels.

Abstract: A metal spraying apparatus comprises a gun having convergent guide passages (36,38) through which metallic wires are fed. An electrical potential is applied across the wires, by conductor elements (54), to cause arcing between the wires where they emerge from the guide passages, which melts the wires. A stream of compressed air causes molten metal droplets to be carried from the arcing zone towards the surface to which a metallic coating is to be applied. The apparatus also comprises a supplying device, to supply electricity and air under pressure to the gun. The conductor elements extend within conduits (18) through which air is fed to the gun, and the gun comprises a valve (9) for cutting off the flow of air through the gun. The supplying device comprises a control device (82) which is responsive to such cut off, to cut off the supply of electricity to the gun.

Abstract: A flame spray gun (10) for feeding and melting rods (R) of heat fusible material and spraying molten droplets thereof onto a substrate comprising an improved main supply valve connected to air, fuel gas and oxidant conduits (14-22) (44-48) including air, fuel gas and oxidant inlet and outlet chambers (28-38), continuous seals (40) and vents (42) between the chambers, a valve shaft (50) with axially spaced slots movable within a bore and seals to connect the inlet and outlet chambers, a valve locking device (54-56) for maintaining shaft (50) either in a LIGHTING or ON position and an unlocking device (62-66) to release biased valve shaft to an OFF position. An improved combustion head (70) and flame spray nozzle (82) has seals situated on opposite sides of oxidant and fuel gas chambers and between the combustion head and nozzle.