Abstract: The present invention provides an improved nozzle assembly for use with a thermal spray apparatus for applying a coating to a workpiece. The nozzle assembly including a housing supporting a nozzle defining a gas conduit having an inlet and an outlet at opposing ends of the housing. The inlet for receiving a carrier medium from a thermal spray apparatus. The housing and the nozzle cooperating to define a material feed opening such that the material feed opening intersects the gas conduit proximate the outlet end of the nozzle. The material feed opening being angularly disposed relative to the gas conduit and intersecting the gas conduit proximate the outlet end of the nozzle such that coating material injected into the gas conduit through the material feed opening is heat-softened and propelled towards a workpiece to be coated by the carrier medium flowing outwardly from the nozzle.

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.