Abstract: A process for forming a substantially planar porous metal coating on a substrate which comprises thermal spraying of the metal on the substrate to form a porous metal coating on the substrate, rolling the sprayed coating to render it substantially planar and in the process close the pores, and then removing part of the surface to improve planarity and to reopen the surface-connected pores of the surface. The metal to be sprayed may be in the form of a wire, powder or molten metal mass and be selected from the group consisting of aluminum, zinc, tin, copper, nickel, or their alloys. Preferably, the substrate is selected from the group consisting of steel, aluminum, aluminized or galvanized steel, tin plate, and plastic. The spraying is preferably conducted in a non-oxidizing or reducing atmosphere. Preferably, the coating on the substrate is subjected to cold rolling. Most preferably, the rolling is conducted so as to reduce the coating thickness to approximately half of its original thickness.

Abstract: An apparatus and method for spray metallizing a coating of metal (e.g., zinc) onto one or both sides of a base metal (e.g. steel). One embodiment of the invention comprises melting the metal to be deposited, propelling first and second streams of the melted metal towards the base metal at a point of convergence adjacent to the substrate, and applying a potential difference between the streams to form an electric arc whereby superheated particles are deposited on the base metal. A second embodiment of the invention comprises melting the metal to be deposited, propelling a stream of the melted metal towards the base metal through a nozzle containing a non-consumable stationary electrode, and applying a potential difference between the molten metal and the electrode to form an electric arc whereby superheated particles are deposited on the base metal.

Abstract: An apparatus and method for spray metallizing a coating of metal (e.g. zinc) onto one or both sides of a base metal (e.g. steel) which comprises melting the metal to be deposited, propelling first and second streams of the melted metal towards the base metal at a point of convergence adjacent to the substrate, and applying a potential difference between the streams to form an electric arc whereby superheated particles are deposited on the base metal.