Abstract: The invention relates to a novel thermal spray process for the deposition of coatings with a graded or layered composition and the coated articles produced thereby. More particularly, the invention relates to feeding mixtures of coating materials to a thermal spray device and continuously or intermittently changing the composition of the deposited coatings by changing the thermal spray operating parameters. The continuous or intermittent change in the composition of the coating material during deposition creates a graded or layered coating structure.

Abstract: The invention relates to a novel thermal spray process for the deposition of coatings with a graded or layered composition and the coated articles produced thereby. More particularly, the invention relates to feeding mixtures of coating materials to a thermal spray device and continuously or intermittently changing the composition of the deposited coatings by changing the thermal spray operating parameters. The continuous or intermittent change in the composition of the coating material during deposition creates a graded or layered coating structure.

Abstract: The invention relates to a novel thermal spray process for the deposition of coatings with a graded or layered composition and the coated articles produced thereby. More particularly, the invention relates to feeding mixtures of coating materials to a thermal spray device and continuously or intermittently changing the composition of the deposited coatings by changing the thermal spray operating parameters. The continuous or intermittent change in the composition of the coating material during deposition creates a graded or layered coating structure.

Abstract: A tungsten chromium carbide-nickel coated article and process for producing it in which the coating contains chromium-rich particles having at least 3 times more chromium than tungsten and wherein said chromium-rich particles comprise at least about 4.5 volume percent of the coating.

Abstract: A tungsten chromium carbide-nickel coated article and process for producing it in which the coating contains chromium-rich particles having at least 3 times more chromium than tungsten and wherein said chromium-rich particles comprise at least about 4.5 volume percent of the coating.

Abstract: The occurrence of defects on wire coated with an aluminum-zinc alloy coating applied by hot dipping in a molten coating bath is substantially decreased by preventing the deposition of zinc powder particles upon the surface of the molten aluminum-zinc coating prior to solidification of the coating. The deposition of metallic zinc powder particles upon the molten aluminum-zinc coating may be alleviated in several different manners, including preventing the formation of the zinc powder, preventing the accumulation of the zinc powder upon the surface of the molten aluminum-zinc bath, decomposing the zinc powder before it accumulates and exhausting or removing the zinc powder from the vicinity of the molten metal coated wire as it leaves the molten bath. Several novel apparatus arrangements for accomplishing the above are disclosed.

Abstract: A gas wiping die for wiping wire issuing from a molten metal coating bath is provided with critical parameters with respect to the die angle, the length and thickness of the die orifice and the relationship of the sides of the orifice, the throat diameter of the die and the height above the molten bath surface. The thickness of molten coatings on wire wiped with the combined die can be very accurately controlled by changes in wiping gas pressure.

Abstract: The occurrence of defects on wire coated with an aluminum-zinc alloy coating applied by hot dipping in a molten coating bath is substantially decreased by preventing the deposition of zinc powder particles upon the surface of the molten aluminum-zinc coating prior to solidification of the coating. The deposition of metallic zinc powder particles upon the molten aluminum-zinc coating may be alleviated in several different manners, including preventing the formation of the zinc powder, preventing the accumulation of the zinc powder upon the surface of the molten aluminum-zinc bath, decomposing the zinc powder before it accumulates and exhausting or removing the zinc powder from the vicinity of the molten metal coated wire as it leaves the molten bath. Several novel apparatus arrangements for accomplishing the above are disclosed.

Abstract: A combined gas wiping die and closed protective atmosphere chamber for treating linear material issuing from a molten metal coating bath is provided with gas exit orifices leading from the hood to the external environment. The gas exit orifices have a combined cross sectional area less than the total cross sectional area of the throat of the wiping die. The combined wiping die and protective chamber with limited area exit orifices is used with a wiping gas such as nitrogen or argon. The thickness of molten coatings on linear material wiped with the combined die and protective chamber can be very accurately controlled by changes in wiping gas pressure.