Abstract: A two stage kinetic energy spray device has a first stage first nozzle having a receiving end that receives a particulate stream, an injection end located axially to the first nozzle receiving end, the injection end receiving the particulate stream from the receiving end. A second stage has a second nozzle, the second nozzle having a gas receiving portion that receives an effluent gas, a convergent portion that is downstream from the gas receiving portion and a divergent portion that is downstream from the convergent portion, the convergent portion and the divergent portion meeting at a throat. The particle stream is accelerated to a first velocity in the first nozzle located within the second nozzle divergent portion The effluent gas is accelerated to a second velocity in the second nozzle. First nozzle injection end chevrons allow mixing of particulate and supersonic effluent streams prior to exiting the spray device.

Abstract: Method for performing a thermal spray process. Method includes heating and/or accelerating a gas to form an effluent gas stream, feeding a particulate-bearing carrier stream through an axial injection port into the effluent gas stream to form a mixed stream, in which the axial injection port includes a plurality of chevrons located at a distal end of said axial injection port, and impacting the mixed stream on a substrate to form a coating.

Abstract: Method for performing a thermal spray process. Method includes heating and/or accelerating a gas to form an effluent gas stream, feeding a particulate-bearing carrier stream through an axial injection port into the effluent gas stream to form a mixed stream, in which the axial injection port includes a plurality of chevrons located at a distal end of said axial injection port, and impacting the mixed stream on a substrate to form a coating.

Abstract: A two stage kinetic energy spray device has a first stage first nozzle having a receiving end that receives a particulate stream, an injection end located axially to the first nozzle receiving end, the injection end receiving the particulate stream from the receiving end. A second stage has a second nozzle, the second nozzle having a gas receiving portion that receives an effluent gas, a convergent portion that is downstream from the gas receiving portion and a divergent portion that is downstream from the convergent portion, the convergent portion and the divergent portion meeting at a throat. The particle stream is accelerated to a first velocity in the first nozzle located within the second nozzle divergent portion The effluent gas is accelerated to a second velocity in the second nozzle. First nozzle injection end chevrons allow mixing of particulate and supersonic effluent streams prior to exiting the spray device.

Abstract: An improved thermal spray apparatus and method of promotes mixing of axially fed particles in a carrier stream with a heated effluent stream without introducing significant turbulence into either the effluent or carrier streams. An axial injection port includes a plurality of chevrons at the distal end of the port. The chevrons are located radially around the circumference of the distal end of the axial injection port to increase the shared area between the two flow streams at the outlet of the port.

Abstract: An improved thermal spray apparatus and method of promotes mixing of axially fed particles in a carrier stream with a heated effluent stream without introducing significant turbulence into either the effluent or carrier streams. An axial injection port includes a plurality of chevrons at the distal end of the port. The chevrons are located radially around the circumference of the distal end of the axial injection port to increase the shared area between the two flow streams at the outlet of the port.

Abstract: A method is disclosed that sets at least one particle-specific parameter in a thermal spray process in which particles are transported by means of a fluid flow from a thermal spray apparatus to a substrate. A first step includes predetermining a target value for the particle-specific parameter, followed by a second step of preparing an operating model for one of the thermal spray process and the thermal spray apparatus with which a simulation of the thermal spray process can be carried out, with the operating model including set values whose variation effects changes in the particle-specific parameter. Next, a third step involves evaluating the operating model for at least one set of starting values for the set values, followed by a fourth step of setting the particle-specific parameter to the target value by an automatic optimisation procedure in which the set values are varied until the target value for the particle-specific parameter results from the operating model.

Abstract: A method is proposed for the determination of process parameters in a thermal spraying process, in which particles are melted or made plastic or vaporized by means of a thermal spraying apparatus (1) and are transported by a flow of fluid (G) to a substrate (6). In said method an operating model is constructed for the thermal spraying process or for the thermal spraying apparatus, with which a simulation of the thermal spraying process can be done and which includes a flow mechanical model and also an electromagnetic model, wherein the flow mechanical model and the electromagnetic model are coupled together and at least one process parameter is determined by means of the operating model.