Abstract: Method and apparatus for monitoring and diagnosing gun performance is derived that can determine proper gun operation and if not operating properly diagnose potential causes for abhorrent operation. The voltage produced by the gun is sampled in real time and the frequency spectrum produced analyzed using FFT and then reducing the FFT pattern down to a set of numerical values or a signature that can be compared to known signatures for both correct operation and abnormal operation. Using best fit techniques the cause of any abnormal behavior can then be identified. The method can also be used to predict the end of hardware life and aid in production scheduling and spare parts acquisition by providing advanced notice of wear and usage.

Abstract: Nozzle for thermal spray gun, thermal spray gun and method for forming nozzle. Nozzle includes a nozzle body having a central bore and an exterior surface structured for insertion into a thermal spray gun and a water coolable surface coating applied onto at least a portion of the exterior surface. The water coolable surface coating is structured to protect the exterior surface from a chemical interaction with cooling water guided through the thermal spray gun.

Abstract: Powder flow conveying from a powder feeder to a process (i.e. thermal spray gun) can have instabilities that can be detected and diagnosed using a hose back pressure. Incorporating a pressure transducer in a powder hose line at a connection of the powder hose line and the feeder allows the back pressure to be measured in real time at a high sample rate to detect instability and aid in diagnosing a cause of the instability. Diagnosis includes identifying periodic oscillations in the powder hose line such as acoustics as well as detecting hose clogging and hose rupture conditions. Once detected, proper corrective actions can be recommended to correct the cause of the instability.

Abstract: A method for determining real time liquid phase flow rate from a biphase stream includes the steps of: providing a stream of a biphase fluid including a gas phase having a known gas density and a liquid phase having a known liquid density; providing a separator having a known volume gradient corresponding to liquid level in the separator; feeding the stream to the separator so as to provide a separated liquid phase containing a portion or the gas phase as entrapped gas and a separated free gas phase in the separator; measuring density of the separated liquid phase; measuring change in level over time of the separated liquid phase in the separator; and determining a liquid phase flow rate from the change in level over time, the separated liquid phase density, the known gas density and the known liquid density.