Abstract: A thermal spraying method involves the creation of a coating comprising titanium wire in the presence of nitrogen. The apparatus of the invention comprises a nozzle which has a cylindrical throat, with feedstock guides which guide the feedstock wires to a point of intersection in the throat. A current is passed through the wires to cause an arc in the throat, and a nitrogen rich gas under pressure is forced through the throat, generating a spray of molten particles which is used to coat a substrate. In a variation of the method, one of the feedstock wires comprises a binder metal, which produces a coating having enhanced toughness.

Abstract: A thermal spraying method involves the creation of a coating comprising titanium wire in the presence of nitrogen. The apparatus of the invention comprises a nozzle which has a cylindrical throat, with feedstock guides which guide the feedstock wires to a point of intersection in the throat. A current is passed through the wires to cause an arc in the throat, and a nitrogen rich gas under pressure is forced through the throat, generating a spray of molten particles which is used to coat a substrate. In a variation of the method, one of the feedstock wires comprises a binder metal, which produces a coating having enhanced toughness.

Abstract: A thermal spraying method involves the creation of a coating comprising titanium wire in the presence of nitrogen. The apparatus of the invention comprises a nozzle which has a cylindrical throat, with feedstock guides which guide the feedstock wires to a point of intersection in the throat. A current is passed through the wires to cause an arc in the throat, and a nitrogen rich gas under pressure is forced through the throat, generating a spray of molten particles which is used to coat a substrate. In a variation of the method, one of the feedstock wires comprises a binder metal, which produces a coating having enhanced toughness.

Abstract: A thermal spray system includes a combustion unit connected to at least one port for supplying a flow of a combustible fluid from an external source of fuel and oxidant. The combustion unit includes a permeable burner block constructed to receive said combustible fluid from and to generate a high-energy stream of gas. The thermal spray system also includes an exhaust nozzle constructed to direct the high-energy stream of gas toward a substrate, and a material delivery unit constructed to deliver a material into the high-energy stream of gas to form a highly energized stream of particles. When the thermal spray system is used for bead blasting, the provided material is an abrasive material. Alternatively, when the thermal spray system is used for coating a substrate, the provided material is a coating material. The material delivery unit may be an injector or an electric arc unit.