Abstract: A method of coating a fiber-reinforced composite material includes providing a fiber-reinforced composite workpiece, treating a surface of the workpiece to remove at least a portion of a polymer matrix and to expose fibers to a treated surface of the workpiece, and coating the treated surface of the workpiece using a thermal spray coating process. The treatment can include laser ablating or applying a peel ply process. The method yields a coated fiber-reinforced composite workpiece with the coating being bonded directly to the fibers via diffusion of the coating into the fibers, the formation of an intermediate compound at an interface of the coating and the fibers, or both.

Abstract: The invention recites a plasma-arc spray gun comprising a cathode and an anode defining a longitudinal axis. The anode further includes an external surface and an internal chamber, the internal chamber extending from a first end to a second end. At least a portion of the internal chamber is defined by revolving a non-linear curve about the longitudinal axis. The plasma-arc spray gun also includes a gun body supporting the cathode and the anode.

Abstract: The invention recites a plasma-arc spray gun comprising a cathode and an anode defining a longitudinal axis. The anode further includes an external surface and an internal chamber, the internal chamber extending from a first end to a second end. At least a portion of the internal chamber is defined by revolving a non-linear curve about the longitudinal axis. The plasma-arc spray gun also includes a gun body supporting the cathode and the anode.

Abstract: A method for preparing and coating metal cookware having an interior cooking surface and for the application of a lubricative coating is disclosed. The method includes mechanically spraying the interior cooking surface with an aluminum oxide material to produce a roughened surface and applying by thermal spraying a metallic abrasion resistant layer of substantially pure titanium, titanium oxide and/or titanium nitride. Also disclosed is a cooking utensil having a substrate and an intermediate layer deposited on the substrate by thermally spraying the substrate with a mechanically durable material, said mechanically durable material being selected from the group consisting of chemically pure titanium, titanium-aluminum, nickel-titanium, and titanium 6-4.

Abstract: The present invention comprises a method for preparing a surface for application of a non-stick coating, the method wherein the surface to be prepared for non-stick coating is prepared by thermally spraying a stainless steel alloy containing at most 6.0% aluminum, and is substantially free of Nickel. The present invention further includes a cooking utensil having a substrate to which an intermediate layer, for receiving the non-stick coating, is prepared by thermally spraying the stainless steel alloy containing at most 6.0% aluminum, and is substantially free of Nickel.

Abstract: An improved plasma arc spray gun performs with higher deposition efficiency and longer lasting anodes and cathodes than prior spray guns. The spray gun of the invention includes a housing made of a glass fiber reinforced TORLON material that remains dimensionally stable under all operating conditions. The anode of a relatively low velocity subsonic spray gun has an interior with five sections, two of which have cylindrical inner surfaces and three of which have frusto-conical surfaces. The cathode tip is carefully located within the anode interior such that the electrical arc between the anode and cathode attaches to the anode at a circular line at a junction of a cylindrical surface and a frusto-conical surface. Relatively high velocity subsonic versions of the plasma arc spray gun utilize anodes with three interior sections and streamlined passages for vortex stabilized flow of the primary gas.