Abstract: A coating (4) that is metallurgically bonded to a metal substrate (2) to protect the substrate includes carbide precipitates (10) of irregular and angular shape and a matrix (12) in which the precipitates are embedded. In a flame spraying procedure that utilizes a wire having a metal case and a core containing metal carbides, metals are deposited on the substrate as a basic coating. When that coating is subjected to a carbon rich environment, the carbon unites with the more reactive metals in the basic coating to form carbide precipitates of those metals, leaving the remaining metals to form the matrix. The carbide precipitates possess irregular and angular configurations and remain firmly embedded in the matrix, even though some of the matrix may disappear through the effects of erosion, corrosion, abrasion or wear.

Abstract: A method for impregnating a metal injected material to produce a composite article (10). The method includes the steps of forming a green part (12) from a feedstock (14), removing a binder (16) from the green part (12) to form a brown part (18), and impregnating the brown part (18) with select particles (20) to form a finished composite article (10).

Abstract: A wire (2) for use as a feedstock in metal spraying and in welding contains two components (4, 6) formed from different metals, with the components being in face-to-face contact along a convoluted interface (8) that extends throughout the interior of the wire. This leaves the distribution of the two metals in generally uniform throughout the cross section of the wire. To produce the wire, two flat strips (22, 22 or 30, 32) of the different metals are provided, with the strips (22, 32) of the second component overlying the strips (20, 30) of the first component to form a laminate (24, 34). Then the laminate is deformed into a U-shaped configuration with the second strip being confined within the first strip. Next the ends of the U-shaped laminate are turned inwardly. The resulting configuration, which has a convoluted interface, is drawn through a die to reduce its cross-sectional size and to densify it.

Abstract: A wire-like product (10) for use as a feedstock in metal or plasma spraying or welding includes a metal case (12) and a composite core (14) in the case, with the core being partially sintered and containing enough metal to conduct an electrical current. To form the wire-like product, a metal tubular segment (20) is filled with a powder (26) in the absence of oxygen. Then the tubular segment is reduced in cross-section to compact the powder within it. Next the tubular segment is heated to anneal it and effect a partial sinter (32) of the powder. Another reduction in cross section breaks the partial sinter into particles and further compacts them, whereas a further heating anneals the tubular segment and resinters the particles. Repetitions of the cycle produce the wire-like product.

Abstract: A cooling fixture for thermal spraying includes a rotatable tubular member for supporting a tubular substrate such as for an oxygen sensor. A cooling tube extends from the tubular member into an open end of the substrate so as to delimit an annular channel therein. The other end of the substrate is closed. Air is forced through the cooling tube into the substrate and thence out via the annular channel, to cool the substrate during thermal spray coating of the outside surface.