Abstract: The present invention is directed at a plasma torch and methods of plasma spraying wherein the delivery of plasma and spray material occurs at extended locations from the anode arc root attachment. Relatively high specific power and relatively high enthalpy plasmas are employed along with a plasma extension module to deliver a plasma spray at a remote location with a minimum enthalpy value.

Abstract: The present invention is directed at a plasma torch and methods of plasma spraying wherein the delivery of plasma and spray material occurs at extended locations from the anode arc root attachment. Relatively high specific power and relatively high enthalpy plasmas are employed along with a plasma extension module to deliver a plasma spray at a remote location with a minimum enthalpy value.

Abstract: The present disclosure generally relates to systems, apparatus and methods of plasma spraying and plasma treatment of materials based on high specific energy molecular plasma gases that may be used to generate a selected plasma. The present disclosure is also relates to the design of plasma torches and plasma systems to optimize such methods.

Abstract: The present disclosure generally relates to systems, apparatus and methods of plasma spraying and plasma treatment of materials based on high specific energy molecular plasma gases that may be used to generate a selected plasma. The present disclosure is also relates to the design of plasma torches and plasma systems to optimize such methods.

Abstract: A composite powder for a deposition of a composite coating comprises a nonmetallic component and a metallic component, the metallic component having an amorphous structure or a nanocrystalline structure. The metallic component may include an amorphous metallic alloy. The metallic alloy may include constituents having the amorphous structure. The metallic component may include a combination of the metallic alloy existing in the amorphous state and constituents of the amorphous metallic alloy in the amorphous state. The composite metal-ceramic powders are used for depositing composite coatings on a selected surface. Disclosed are several methods and systems for producing such composite powders. Disclosed are also several methods and systems for depositing composite coatings. Advantageously, the deposited coatings exhibit high corrosion resistance, high wear resistance, and excellent structural properties.

Abstract: A composite powder for a deposition of a composite coating comprises a nonmetallic component and a metallic component, the metallic component having an amorphous structure or a nanocrystalline structure. The metallic component may include an amorphous metallic alloy. The metallic alloy may include constituents having the amorphous structure. The metallic component may include a combination of the metallic alloy existing in the amorphous state and constituents of the amorphous metallic alloy in the amorphous state. The composite metal-ceramic powders are used for depositing composite coatings on a selected surface. Disclosed are several methods and systems for producing such composite powders. Disclosed are also several methods and systems for depositing composite coatings. Advantageously, the deposited coatings exhibit high corrosion resistance, high wear resistance, and excellent structural properties.

Abstract: A composite powder for a deposition of a composite coating comprises a nonmetallic component and a metallic component, the metallic component having an amorphous structure or a nanocrystalline structure. The metallic component may include an amorphous metallic alloy. The metallic alloy may include constituents having the amorphous structure. The metallic component may include a combination of the metallic alloy existing in the amorphous state and constituents of the amorphous metallic alloy in the amorphous state. The composite metal-ceramic powders are used for depositing composite coatings on a selected surface. Disclosed are several methods and systems for producing such composite powders. Disclosed are also several methods and systems for depositing composite coatings. Advantageously, the deposited coatings exhibit high corrosion resistance, high wear resistance, and excellent structural properties.

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.