Abstract: A powder feed assembly comprises a powder hopper, a motor, an auger housing, an auger, a porous gas-permeable powder filter, a carrier gas inlet, an auger sleeve, and a powder hose. The auger housing receives a powder from the opening in the hopper floor into a powder chamber defined in the auger housing. The auger is selectively rotatable to propel the powder from the powder chamber past the distal end of the auger and into the auger sleeve. The carrier gas inlet introduces carrier gas into an inner chamber of the auger housing. The wall of the auger sleeve allows at least some of the carrier gas to flow or permeate into the internal bore of the auger sleeve to pick up and carry the propelled powder out of the auger housing. The powder hose directs the carrier gas and carried powder from the auger housing to a powder dispenser.

Abstract: A powder feed assembly comprises a powder hopper and a selectively rotating blade. The powder hopper has a wall and a floor together forming a chamber. A circumferential horizontal gap is defined between the wall and the floor to enable powder to exit the chamber. The selectively rotating blade has a body portion positioned within the chamber and one or more blade portions at least partially extending into the gap.

Abstract: A powder feed assembly comprises a powder hopper and a selectively rotating blade. The powder hopper has a wall and a floor together forming a chamber. A circumferential horizontal gap is defined between the wall and the floor to enable powder to exit the chamber. The selectively rotating blade has a body portion positioned within the chamber and one or more blade portions at least partially extending into the gap.

Abstract: A gas dynamic cold spray gun comprises a gun housing, a permeable body arranged inside the gun housing having a carrier gas inlet at a first end and a carrier gas outlet at a second end, an induction coil surrounding the permeable body and connected to a power supply, a nozzle affixed to the carrier gas outlet of the permeable body, and an orifice located downstream of the nozzle connected to a powder feeder.

Abstract: A thermal spray system includes a combustion unit connected to at least one port for supplying a flow of a combustible fluid from an external source of fuel and oxidant. The combustion unit includes a permeable burner block constructed to receive said combustible fluid from and to generate a high-energy stream of gas. The thermal spray system also includes an exhaust nozzle constructed to direct the high-energy stream of gas toward a substrate, and a material delivery unit constructed to deliver a material into the high-energy stream of gas to form a highly energized stream of particles. When the thermal spray system is used for bead blasting, the provided material is an abrasive material. Alternatively, when the thermal spray system is used for coating a substrate, the provided material is a coating material. The material delivery unit may be an injector or an electric arc unit.