Abstract: The invention contemplates improved nozzle structure removably securable to a gas-distributor body for delivering and discharging independent flows of combustible-gas mixture and of powder material to be flame-sprayed by a gas torch to which the nozzle is fitted. The combustible-gas mixture is successively accommodated in annular manifold regions of relatively large sectional area, respectively upstream and downstream from an intermediate annular manifold region of relatively restricted sectional area, for inhibiting flash-back to the gas distributor and for effectively limiting any flash-back effects to the manifold region downstream of the annular restriction.

Abstract: The invention contemplates a powder-feeding system for gas-propelled delivery of a powder to be controllably supplied, as to a flame-spraying gas torch or to a transferred-arc plasma torch. A fluidizing chamber receives (a) fluidizing-gas flow from below a porous screen, and (b) a restricted gravitational flow of powder at a relatively small central discharge location above the porous screen. A gas conduit extends transversely through the chamber between the powder-discharge location and the porous screen; it has a carrier-gas supply connection at one end and a gas-propelled powder-delivery connection at its other end. The conduit also has an upwardly extending opening virtually beneath and facing the powder-discharge location, but a shed interposed between this opening and the powder-discharge location sufficiently overlaps the opening to assure that no powder will pass through the opening and into the conduit unless it has been gas-fluidized.

Abstract: The invention contemplates a gas-torch construction wherein independent flows of combustible gases are maintained up to the point of mixing within the nozzle of the torch, virtually at the location of discharge from the nozzle. The nozzle is removably connected to an elongate intermediate or adapter member, and the latter is removably connected to the torch body. The separate flows of the gases are maintained independent of each other, from the torch body, through the adapter member, and into the upstream end of the mixing nozzle. Individual radially spaced manifolds at the adapter-to-nozzle connection assure independence of the gas flows and a non-critical angular relation when the nozzle is replaced. The invention is described in application to a powder-spraying gas torch, as for torch deposition of metal coatings.

Abstract: A free-flowing self-bondable flame spray powder derived from an atomized alloy powder is provided in which the particles are characterized by aspherical shapes and have an average particle size within the range of about plus 400 mesh to minus 100 mesh. The aspherically shaped powder is further characterized by a specific surface of about 180 cm.sup.2 /gr and higher and has a composition consisting essentially by weight of up to about 0.1% C, about 3% to 30% Mo, up to about 3% Si, up to about 6% W, about 2.5% to 12% Ti, about 10% to 22% Fe, up to about 0.4% V, and the balance essentially nickel.

Abstract: A free-flowing self-bondable flame spray powder derived from an atomized alloy powder is provided in which the particles are characterized by aspherical shapes and have an average particle size within the range of about plus 400 mesh to minus 100 mesh. The aspherically shaped powder is further characterized by an specific surface of about 180 cm.sup.2 /gr and higher and has a composition consisting essentially of a solvent metal alloy selected from the iron-group base alloys consisting of nickel-base, iron-base, and cobalt-base alloys containing by weight about 5% to 35% chromium, the solvent metal alloy having a negative free energy of oxidation ranging up to about 80,000 calories per gram atom of oxygen referred to 25.degree. C. and containing about 5% to 15% by weight of a highly oxidizable solute metal whose negative free energy of oxidation is at least about 100,000 calories per gram atom of oxygen referred to 25.degree. C.

Abstract: A free-flowing self-bondable flame spray powder derived from an atomized alloy powder is provided in which the particles are characterized by aspherical shapes and have an average particle size within the range of about plus 400 mesh to minus 100 mesh. The aspherically shaped powder is further characterized by a specific surface of about 180 cm.sup.2 /gr and higher and has a composition consisting essentially of a solvent metal of melting point in excess of about 1100.degree. C. whose negative free energy of oxidation ranges up to about 80,000 calories per gram atom of oxygen referred to 25.degree. C. The solvent metal contains at least one highly oxidizable solute metal in an amount of at least about 3% by weight, the oxidizable metal having a negative free energy of oxidation of at least about 100,000 calories per gram atom of oxygen referred to 25.degree. C.

Abstract: The invention contemplates an elongate extension nozzle attachment for a gas torch whereby flame-spraying of coating-powder material may be applied with precision to the bore of a workpiece. The attachment is detachably securable to conventional torch and/or gas-distributor structure and provides independent flows of (a) carrier gas and powder and (b) combustible-gas mixture to a nozzle which is removably fitted to the discharge end. Provision is made for optional use of one or more flame-shaping discharges of air, inert gas or the like at the discharge end, using a further independent supply system within the attachment.

Abstract: The invention contemplates a selectively operative flame-shaping feature in application to a powder-spraying gas torch, whereby directional jets of compressed-air or other pressure fluid may be discharged into angularly spaced off-axis regions of a developing flame spray, with selective rotational adjustment of the angular orientation of jet discharge with respect to the axis of flame-spray discharge.

Abstract: A flame spray powder mix is provided for producing metal coatings on metal substrates, such as ferrous metal substrates, e.g., steel, case iron, among other metal substrates, the powder mix comprising particles of at least one metal silicide, e.g., titaniium disilicide, mixed with a coating metal powder, such as nickel powder. The amount of metal silicide in the powder mix preferably ranging from about 2% to 20% by weight.

Abstract: A flame spray powder mix is provided for producing coatings on metal substrates, such as substrates of steel, cast iron, non-ferrous metals, among other substrates, the powder mix comprising agglomerates of a metallo-thermic heat generating composition (i.e., a thermic composition, such as an alumino-thermic composition) mixed with at least one coating material, such as metal and/or non-metal coating materials.

Abstract: A flame spray powder mix is provided for producing metal coatings on metal substrates, such as ferrous metal substrates, e.g., steel, cast iron, among other metal substrates, the powder mix comprising agglomerates of silicon and at least one metal disilicide, e.g., titanium disilicide, homogeneously mixed or blended with a coating metal powder, such as nickel powder.

Abstract: A flame spray powder mix or blend is provided for producing metal coatings on metal substrates, such as ferrous metal substrates, e.g., steel, cast iron, among other metal substrates, the powder mix comprising agglomerates of at least one oxidizable metal, e.g., aluminum, homogeneously mixed or blended with a coating metal powder, such as nickel powder. The coating produced is characterized by a strong bond and also being substantially low in dispersed oxides.

Abstract: A flame spray powder mix is provided for producing metal coatings on metal substrates, such as ferrous metal substrates, e.g. steel, cast iron, among other metal substrates, the powder mix comprising agglomerates of at least one metal silicide, e.g. titanium disilicide, homogeneously mixed with a coating metal powder, such as nickel powder. The mix may additionally contain agglomerates of silicon powder with the coating metal powder making up the major portion of the powder mix.

Abstract: A nickel-base wear and corrosion resistant alloy is provided containing by weight about 20% to 35% Cr, about 1% to 8% Si, about 1.7% to 3.5% C, 0 to 15% W and the balance essentially at least about 40% nickel, the amount of carbon present in said composition being stoichiometrically related to the chromium content to provide carbides based on the formula M.sub.7 C.sub.3, wherein M comprises essentially chromium, the amount of chromium in said M.sub.7 C.sub.3 compound ranging from about 65% to less than about 100% of the total chromium in said composition, the melting point of said alloy being less than about 1350.degree. C. The alloy has particular use in welding consumables for hard facing, for valve seats, for wear resistant sleeves and bushings (castings) and other uses.

Abstract: A flame spray powder mix is provided for producing coatings on metal substrates, such as substrates of steel, cast iron, non-ferrous metals, among other substrates, the powder mix comprising agglomerates of a metallo-thermic heat generating composition (i.e., a thermit composition, such as an alumino-thermic composition) mixed with at least one coating material, such as metal and/or non-metal coating materials.

Abstract: A copper-aluminum alloy flame spray powder is provided consisting essentially by weight of 0 to about 5% Fe, about 2% to 8% Ni, about 5% to 15% Al, and the balance essentially copper, a coating produced from said powder being characterized by improved as-sprayed hardness in combination with resistance to oxidation and galling.

Abstract: The method of the invention employs a gas torch which has the feature of selective addition of metal powder to the gas flow, in a cyclical pattern of metal-spraying and non-spraying (fusing) utilization of the same torch. The torch is caused to make short and relatively rapid transverse oscillations of sweep across the width of a swath along the workpiece, the swath developing in the course of a relatively slow feed (e.g., a longitudinal feed) of the torch with respect to the workpiece. The rate of torch feed and the duty cycle of metal application (vs. non-spraying) are related to the effective width of the metal "bead" thus sprayed, so as to assure (1) overlapping of adjacent beads and (2) fusing of adjacent beads to each other and to the workpiece.

Abstract: A flame spray powder mix is provided for producing metal coatings on metal substrates, such as ferrous metal substrates, e.g. steel, cast iron, among other metal substrates, the powder mix comprising agglomerates of at least one metal silicide, e.g. titanium disilicide, homogeneously mixed with a coating metal powder, such as nickel powder. The mix may additionally contain agglomerates of silicon powder with the coating metal powder making up the major portion of the powder mix.

Abstract: A flame spray powder mix is provided for producing metal coatings on metal substrates, such as ferrous metal substrates, e.g., steel, cast iron, among other metal substrates, the powder mix comprising agglomerates of silicon and at least one metal disilicide, e.g., titanium disilicide, homogeneously mixed or blended with a coating metal powder, such as nickel powder.