Abstract: A feeder apparatus supplies a powder feedstock to a high or low pressure processing operation. The apparatus includes a metering plate defining an annular channel having a channel width. A measuring mechanism dispenses a measured volume of the feedstock into the annular channel. The measuring mechanism includes a pay-out device defining an outlet significantly smaller than the channel width. The measuring mechanism further includes a maximum fill level defining a maximum pressure head in the feedstock less than a retaining pressure defined by the internal friction of the feedstock. The restraining pressure prevents the feedstock from spreading outwardly in the annular channel and contacting sidewalls of the annular channel under the pressure head of the feedstock. The apparatus further includes a pick-up device for removing the feedstock from the annular channel. The pick-up device includes an inlet having a rectangular shape extending across the annular channel.

Abstract: A modified high efficiency kinetic spray nozzle is disclosed. The modified nozzle has a rapid expansion rate in the diverging region relative to prior art nozzles, which enables one to achieve much higher particle velocities without an increase in the main gas temperature. Preferably, the expansion rate of the supersonic nozzle in a portion of the diverging region is at least 1 mm2 per millimeter, more preferably 2 mm2 per millimeter, more preferably 5 mm2 per mm, with a most preferable expansion rate being 10 mm2 per millimeter.

Abstract: A low cost transistor package is provided for high power applications. The package provides high thermal conductivity and dissipation for a silicon transistor die, high current carrying capability and isolation, and high power and thermal cycle life performance and reliability. A dielectric layer is fixed to a silicon transistor die, for coupling to a heat conducting buffer and attachment to a substrate. The dielectric layer is fixed to the die by growing the dielectric layer, depositing the dielectric layer, or applying the dielectric layer using a plasma spray. In an aspect, a conductive layer is formed to the silicon transistor die by a thermal or kinetic spray process, and the dielectric layer is applied to the conductive layer. The dielectric layer may also be established either before or after the transistor fabrication. Electrical and thermal interconnects are advantageously positioned from opposite sides of the silicon transistor die.

Abstract: A new kinetic spray process is disclosed that enables one to secure a plurality of ceramic elements together quickly without the need for glues or other adhesives. The process finds special utilization in the formation of non-thermal plasma reactors wherein the kinetic spray process can be used to simultaneously secure the ceramic elements together and to form electrical connections between like electrodes in the non-thermal plasma reactor.

Abstract: A feeder apparatus supplies a powder feedstock to a high or low pressure processing operation. The apparatus includes a metering plate defining an annular channel having a channel width. A measuring mechanism dispenses a measured volume of the feedstock into the annular channel. The measuring mechanism includes a pay-out device defining an outlet significantly smaller than the channel width. The measuring mechanism further includes a maximum fill level defining a maximum pressure head in the feedstock less than a retaining pressure defined by the internal friction of the feedstock. The restraining pressure prevents the feedstock from spreading outwardly in the annular channel and contacting sidewalls of the annular channel under the pressure head of the feedstock. The apparatus further includes a pick-up device for removing the feedstock from the annular channel. The pick-up device includes an inlet having a rectangular shape extending across the annular channel.

Abstract: An improved nozzle for use in kinetic spray systems is disclosed. The nozzle includes a supersonic portion comprising a tubular section and a flow regulator. A portion of the flow regulator is received in the tubular portion. The flow regulator includes a biconical flow concentrator that allows one to create very small dimension coatings on substrates. Using the present nozzle enables one to create spot coatings and very narrow width line coatings that find use in electrical components.

Abstract: The subject invention detects the presence of an ozone reducing coating on an automotive radiator of the type having spaced fins presenting electromagnetic surface properties different than the electromagnetic surface properties of the coating. In accordance with the subject invention light rays are emitted or reflected off the coating on the fins to a detector and a comparator compares these light rays to a predetermined benchmark to provide a signal in response to the detected light rays crossing the benchmark. In a species, a second detector is employed to detect rays from an un-coated section to establish the benchmark.

Abstract: Disclosed is a process for applying a kinetic spray coating of powder particles onto a substrate covered in a plastic-type material without first removing the plastic-type material. In one use of the process a mask is used to enable a single kinetic spray pass to both remove the plastic covering and bind particles having average nominal diameters of from 60 to 250 microns to the underlying substrate. In another use of the process the particles have an average nominal diameter of from 250 to 1400 microns and the use of a mask is optional because the particles can penetrate the plastic material and bind directly to the substrate. The process finds special use in forming electrical connections or solderable pads anywhere along the length of a flexible circuit.

Abstract: Disclosed is a system and a method for simultaneously applying a kinetic spray coating and a thermal spray coating onto a substrate using a single application nozzle to produce a combined coating. The system may include a higher heat capacity gas heater to permit both the thermal spray and the kinetic spray. The method involves providing two populations of particles to the nozzle simultaneously wherein one population is thermally softened in the nozzle under the spray parameters and the other is not. The system increases the versatility of the spray nozzle and addresses several problems inherent in kinetic spray applied coatings.

Abstract: The subject invention provides an assembly for measuring movement of and a torque applied to a shaft extending between first and second ends and being hollow, specifically for measuring rotation and twisting of the shaft. A permanent magnet is disposed within the shaft for producing a parallel magnetic field emanating radially from the shaft. A sensor mechanism is positioned adjacent the shaft to detect the magnetic flux produced in response to the shaft being moved. The sensor mechanism includes a magnetostrictive (MR) material disposed annularly about the shaft and extends between first and second edges. A flux collector extends beyond the first and second edges of the magnetostrictive material to direct the magnetic flux through a Hall sensor to detect an axial component of the magnetic flux in response to twisting.

Abstract: The present invention is directed to electrical contacts that comprise spaced electrically conductive particles embedded and bonded into the surface of conductors in which the particles have been kinetically sprayed onto the conductors with sufficient energy to form direct mechanical bonds between the particles and the conductors in a pre-selected location and particle number density that promotes high surface-to-surface contact and reduced contact resistance between the conductors.

Abstract: The present invention is directed to a process for preparing aluminum and aluminum alloy surfaces in heat exchangers for brazing by depositing thereon a kinetic sprayed brazing composition. The process simultaneously deposits monolith or composite coatings that can include all braze materials and corrosion protection materials used in the brazing of aluminum fins to plates and tubes in a single stage.

Abstract: A method of maintaining a non-obstructed interior opening in a kinetic spray nozzle is disclosed. The method includes the steps of providing a mixture of particles including first particle population and a second particle population; entraining the mixture of particles into a flow of a gas at a temperature below the melt temperature of the particle populations; and directing the mixture of particles entrained in the flow of gas through a supersonic nozzle to accelerate the first particle population to a velocity sufficient to result in adherence of the first particle population on a substrate positioned opposite the nozzle. The operating conditions of the kinetic spray system are selected such that the second particle population is not accelerated to a velocity sufficient to result in adherence when it impacts the substrate.

Abstract: A new kinetic spray process is disclosed that enables the coating to withstand severe bending and stress without delamination. The method includes use of a low pressure kinetic spray supersonic nozzle having a throat located between a converging region and a diverging region. A main gas temperature is raised to from 1000 to 1300 degrees Fahrenheit and the coating particles are directly injected into the diverging region of the nozzle at a point after the throat. The particles are entrained in the flow of the gas and accelerated to a velocity sufficient to result in partial melting of the particles upon impact on a substrate positioned opposite the nozzle and adherence of the particles to the substrate. The coating also has a desirable shinny surface. The method finds special application in coating substrates for use in formation of electrical connections.

Abstract: The subject invention detects the presence of an ozone reducing coating on an automotive radiator of the type having spaced fins presenting electromagnetic surface properties different than the electromagnetic surface properties of the coating. In accordance with the subject invention light rays are emitted or reflected off the coating on the fins to a detector and a comparator compares these light rays to a predetermined benchmark to provide a signal in response to the detected light rays crossing the benchmark. In a species, a second detector is employed to detect rays from an un-coated section to establish the benchmark.

Abstract: A method is for direct application of a brazing flux material to a brazing surface. The method includes the step of applying a brazing filler material to a substrate utilizing a kinetic spray process to form a brazing surface. Following application of the brazing filler material to the substrate brazing flux material can be directly applied to the brazing surface as either a dry powder or a wet slurry. The nature of the brazing surface allows the applied flux material to adhere to the surface without the utilization of additional binders or resin materials.

Abstract: Disclosed is a method and a nozzle for a kinetic spray system that uses much lower powder pressures than previously used in kinetic spray systems. The method permits one to significantly decrease the cost of the powder delivery portion of the system, to run the system at higher temperatures for increased deposition efficiency and to eliminate clogging of the nozzle. The nozzle is a supersonic nozzle having a throat located between a converging region and a diverging region, with the diverging region defined between the throat and an exit end. At least one injector is positioned between the throat and the exit end with the injector in direct communication with the diverging region. The powder particles to be sprayed are injected through the at least one injector and entrained in a gas flowing through the nozzle. The entrained particles are accelerated to a velocity sufficient to cause them to adhere to a substrate positioned opposite the nozzle.

Abstract: A new kinetic spray process is disclosed that enables the coating to withstand severe bending and stress without delamination. The method includes use of a low pressure kinetic spray supersonic nozzle having a throat located between a converging region and a diverging region. A main gas temperature is raised to from 1000 to 1300 degrees Fahrenheit and the coating particles are directly injected into the diverging region of the nozzle at a point after the throat. The particles are entrained in the flow of the gas and accelerated to a velocity sufficient to result in partial melting of the particles upon impact on a substrate positioned opposite the nozzle and adherence of the particles to the substrate. The coating also has a desirable shinny surface. The method finds special application in coating substrates for use in formation of electrical connections.

Abstract: A kinetically sprayed magnetostrictive/magnetic material, comprising: magnetostriction particles; magnetic particles with coercivity; a ductile matrix for bonding the magnetostriction particles and magnetic particles with coercivity together; wherein an applied magnetic field will align the magnetic particles with coercivity and subsequently the magnetostriction particles such that the magnetostrictive material will produce a detectable change in the magnetostrictive/magnetic material when placed under an applied stress.

Abstract: The present invention is directed to electrical contacts that comprise spaced electrically conductive particles embedded and bonded into the surface of conductors in which the particles have been kinetically sprayed onto the conductors with sufficient energy to form direct mechanical bonds between the particles and the conductors in a pre-selected location and particle number density that promotes high surface-to-surface contact and reduced contact resistance between the conductors.