Plasma Patents (Class 219/76.16)
  • Patent number: 11920217
    Abstract: A titanium alloy for additive manufacturing that includes 5.5 to 6.5 wt % aluminum (Al); 3.0 to 4.5 wt % vanadium (V); 1.0 to 2.0 wt % molybdenum (Mo); 0.3 to 1.5 wt % iron (Fe); 0.3 to 1.5 wt % chromium (Cr); 0.05 to 0.5 wt % zirconium (Zr); 0.2 to 0.3 wt % oxygen (O); maximum of 0.05 wt % nitrogen (N); maximum of 0.08 wt % carbon (C); maximum of 0.25 wt % silicon (Si); and balance titanium, wherein a value of an aluminum structural equivalent [Al]eq ranges from 7.5 to 9.5 wt %, and is defined by the following equation: [Al]eq=[Al]+[O]×10+[Zr]/6, and wherein a value of a molybdenum structural equivalent [Mo]eq ranges from 6.0 to 8.5 wt %, and is defined by the following equation: [Mo]eq=[Mo]+[V]/1.5+[Cr]×1.25+[Fe]×2.5.
    Type: Grant
    Filed: August 31, 2018
    Date of Patent: March 5, 2024
    Assignees: The Boeing Company, VSMPO-AVISMA Corporation
    Inventors: Natalia Mitropolskaya, Robert Briggs, Catherine Parrish, Arash Ghabchi, Matthew Crill, Michael Leder, Igor Puzakov, Alexey Zaitsev, Natalia Tarenkova
  • Patent number: 11773491
    Abstract: Systems and methods for highly reproducible and focused plasma jet printing and patterning of materials using appropriate ink containing aerosol through nozzles with narrow orifice and tubes with controlled dielectric constant connected to high voltage power supply, in the presence of electric field and plasma, that enables morphological and/or bulk chemical modification and/or surface chemical modification of the material in the aerosol and/or the substrate prior to printing, during printing and post printing.
    Type: Grant
    Filed: January 21, 2021
    Date of Patent: October 3, 2023
    Assignee: UNIVERSITIES SPACE RESEARCH ASSOCIATION
    Inventors: Ramprasad Gandhiraman, Meyya Meyyappan, Jessica E. Koehne
  • Patent number: 10995406
    Abstract: Systems and methods for highly reproducible and focused plasma jet printing and patterning of materials using appropriate ink containing aerosol through nozzles with narrow orifice and tubes with controlled dielectric constant connected to high voltage power supply, in the presence of electric field and plasma, that enables morphological and/or bulk chemical modification and/or surface chemical modification of the material in the aerosol and/or the substrate prior to printing, during printing and post printing.
    Type: Grant
    Filed: April 3, 2017
    Date of Patent: May 4, 2021
    Assignee: UNIVERSITIES SPACE RESEARCH ASSOCIATION
    Inventors: Ramprasad Gandhiraman, Meyya Meyyappan, Jessica E. Koehne
  • Patent number: 10738374
    Abstract: There is provided a method of performing a surface treatment with respect to a metal mounting table for mounting a substrate to be plasma-processed, the mounting table functioning as a lower electrode configured to generate a plasma by a high frequency power applied between an upper electrode and the lower electrode. The method includes: performing a first surface treatment by spraying a non-sublimation blast material as a non-sublimation material onto a mounting surface of the metal mounting table on which the substrate is mounted, followed by a second surface treatment by spraying a sublimation blast material as a sublimation material onto the mounting surface.
    Type: Grant
    Filed: January 4, 2017
    Date of Patent: August 11, 2020
    Assignee: TOKYO ELECTRON LIMITED
    Inventors: Shinya Okabe, Hideaki Yamasaki, Junya Oka, Yuuji Kobayashi, Takamichi Kikuchi
  • Patent number: 10071387
    Abstract: A coat forming apparatus 100 includes a droplet supply unit 110 and an active species supply unit 120. The droplet supply unit 110 is adapted to spray or drop a droplet for coat forming toward an object 116. The active species supply unit 120 is adapted to supply an active species to be brought into contact with the droplet moving from the droplet supply unit 110 toward the object 116. The coating is formed on a surface of the object 116 by the droplet that has been brought into contact with the active species.
    Type: Grant
    Filed: September 4, 2012
    Date of Patent: September 11, 2018
    Assignee: IMAGINEERING, INC.
    Inventor: Yuji Ikeda
  • Patent number: 9896760
    Abstract: A deposition apparatus comprises a source unit configured to generate a plasma by arc discharge, a deposition unit in which a deposition target material is arranged so as to be irradiated with the plasma generated in the source unit, and an induction unit configured to induce the plasma for the source unit to the deposition unit. The induction unit comprises a partition unit airtightly connected to each of the source unit and the deposition unit and configured to pass the plasma inside, and a plurality of magnet units configured to form a magnetic field to induce the plasma in the partition unit. The plurality of magnet units are connected to adjust a connection angle, and the partition unit includes a tubular member bendable according to the connection angle of the plurality of magnet units.
    Type: Grant
    Filed: November 4, 2015
    Date of Patent: February 20, 2018
    Assignee: CANON ANELVA CORPORATION
    Inventors: Hidekazu Nishimura, Naoyuki Nozawa
  • Patent number: 9630162
    Abstract: A reactor and method for production of nanostructures, including metal oxide nanowires or nanoparticles, are provided. The reactor includes a regulated metal powder delivery system in communication with a dielectric tube; a plasma-forming gas inlet, whereby a plasma-forming gas is delivered substantially longitudinally into the dielectric tube; a sheath gas inlet, whereby a sheath gas is delivered into the dielectric tube; and a microwave energy generator coupled to the dielectric tube, whereby microwave energy is delivered into a plasma-forming gas. The method for producing nanostructures includes providing a reactor to form nanostructures and collecting the formed nanostructures, optionally from a filter located downstream of the dielectric tube.
    Type: Grant
    Filed: April 4, 2012
    Date of Patent: April 25, 2017
    Assignee: University of Louisville Research Foundation, Inc.
    Inventors: Mahendra Kumar Sunkara, Jeong H. Kim, Vivekanand Kumar
  • Patent number: 9548591
    Abstract: An insulator for a spark plug comprises a first segment surrounding the terminal, a second segment extending from the first segment, and a third segment extending from the second segment. A gap is disposed between the third segment of the insulator and the outer shell. At least one coating having a least one layer is disposed on a surface of the third segment.
    Type: Grant
    Filed: January 28, 2016
    Date of Patent: January 17, 2017
    Assignee: Fram Group IP LLC
    Inventors: Jing Zheng, Jeffrey T. Boehler, Prabhu Megharaj, Philip Treier
  • Patent number: 9457517
    Abstract: A powder shaping method comprises: providing a powder on a target surface; providing a laser beam to illuminate the powder so as to form a pre-treated powder; and providing an energy beam to illuminate the pre-treated powder for enabling a shaping process. In addition, a powder shaping apparatus comprises a base, a target surface, a powder supply unit and an energy beam source system. The target surface is disposed on the base and can be fixed or moved on the base. The powder supply unit provides a powder on the target surface. The energy beam source system has a laser source and an energy source, the laser source provides a laser beam to illuminate the powder to form a pre-treated powder, and the energy source provides an energy beam to further illuminate the pre-treated powder to make a shaping process.
    Type: Grant
    Filed: December 20, 2013
    Date of Patent: October 4, 2016
    Assignee: INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTE
    Inventors: Chung-Wei Cheng, Kuang-Po Chang, Cen-Ying Lin, Shu-Yi Wang
  • Patent number: 9024230
    Abstract: A method of starting a multi-gas plasma arc torch for cutting a workpiece is provided that includes directing a pre-flow gas within the plasma arc torch and switching the pre-flow gas to a plasma gas before a pilot arc is transferred to the workpiece. The plasma gas is supplied initially at a first gas pressure when the pre-flow gas is switched to the plasma gas. The gas pressure is switched to a second gas pressure that is different than the first gas pressure after the pilot arc is transferred. The method provides a smooth transition from the pre-flow gas to the plasma gas and reduces the time delay in replacing the pre-flow gas with the plasma gas in the plasma arc torch, thereby improving cut or marking quality.
    Type: Grant
    Filed: April 13, 2012
    Date of Patent: May 5, 2015
    Assignee: Victor Equipment Company
    Inventors: Daniel Wayne Barnett, Nakhleh Hussary
  • Publication number: 20150060413
    Abstract: A method of depositing a corrosion resistant material via a plasma transferred wire arc (PTWA) thermal spray method on the cylinder surface of heavy duty diesel internal combustion engines. The PTWA process uses a stainless steel hollow core wire that is filled with a metal oxide or carbide powder. The powder can be 100% chromium carbide.
    Type: Application
    Filed: September 4, 2014
    Publication date: March 5, 2015
    Applicant: MAHLE INDUSTRIES, INC.
    Inventor: Thomas SMITH
  • Publication number: 20140360788
    Abstract: In order to provide a nonmagnetic material for producing parts or coatings adapted for highly wear and corrosion intensive applications, said material comprising preformed particles made of tungsten carbide which are embedded in a metal phase made of a Ni-based alloy. It is suggested that the weight portion of said tungsten carbide particles is in the range between 30 wt. % and 65 wt. % and wherein the Ni-based alloy is a Nickel-Chromium-Molybdenum alloy comprising: (in wt. %): Cr 11.0,-30.0? Mo 5.0-25.0? Fe ?0-10.0 B 0-5.0 Co 0-2.
    Type: Application
    Filed: June 10, 2013
    Publication date: December 11, 2014
    Inventors: MICHEL JUNOD, Michael Gill, Alain Tremblay
  • Patent number: 8847098
    Abstract: Devices and methods are contemplated in which a first electrode is circumferentially movable about a second electrode such that a tubular work piece can be resistance welded to a second work piece. Most preferably, the first electrode is a wheel-shaped electrode, while the second electrode is static and disk-shaped.
    Type: Grant
    Filed: July 22, 2010
    Date of Patent: September 30, 2014
    Assignee: Thermal Structures, Inc.
    Inventor: Vaughn V. Barnes
  • Patent number: 8822874
    Abstract: A method and apparatus for microplasma spray coating a portion of a substrate, such as a gas turbine compressor blade, without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects inert gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the compressor blade is coated with the powdered material without having to mask the compressor blade.
    Type: Grant
    Filed: October 31, 2012
    Date of Patent: September 2, 2014
    Assignee: United Technologies Corporation
    Inventors: Paul Zajchowski, Donn Blankenship, Gary C. Shubert
  • Patent number: 8803025
    Abstract: A plasma gun system comprising: a plasma gun comprising an outlet, wherein the plasma gun is configured to generate a plasma stream and provide the plasma stream to the outlet; and a plasma gun extension assembly configured to be coupled to the plasma gun, wherein the plasma gun extension assembly comprises an extension chamber and a port, the extension chamber having an interior diameter defined by a chamber wall and being configured to receive the plasma stream from the outlet of the plasma gun and to enable the plasma stream to expand upon entering the extension chamber, and the port being configured to introduce a powder to the expanded plasma stream at a location outside of the plasma gun.
    Type: Grant
    Filed: December 10, 2010
    Date of Patent: August 12, 2014
    Assignee: SDCmaterials, Inc.
    Inventors: Frederick P. Layman, David Leamon
  • Publication number: 20140166625
    Abstract: The plasma spraying apparatus includes a cathode, a first gas nozzle defining a first gas path between the cathode and itself, a second gas nozzle defining a second gas path between the first gas nozzle and itself, and a third gas nozzle disposed between the first and second gas nozzles to define a third gas path between the first and second gas paths. A wire is disposed at a distal end thereof in front of a nozzle opening of the second gas nozzle. A first gas sprayed through the first gas nozzle is turned into plasma flame, which melts the wire into droplets, and the droplets are sprayed onto a target by a second gas sprayed through the second gas nozzle. The third gas absorbs heat from the plasma flame to thereby turn into a high-temperature gas flow externally of the plasma flame.
    Type: Application
    Filed: December 17, 2012
    Publication date: June 19, 2014
    Applicants: FUJI ENGINEERING CO., LTD., WEST NIPPON EXPRESSWAY COMPANY LIMITED, FUJIGIKEN CO., LTD.
    Inventors: Masanobu SUGIMOTO, Kenichi YAMADA, Masanobu IRIE
  • Publication number: 20140144888
    Abstract: A spray coating apparatus includes a cathode and an anode nozzle to form a pair. A front end of the anode nozzle is provided with three or more plasma jet jetting holes, and a spray material jetting hole is disposed at the center of an area surrounded by the plasma jet jetting holes. The spray material jetted through the jetting hole is fed into the center axis of a complex plasma arc or a complex plasma jet. The spray material jetted through the spray material jetting hole is melted at high thermal efficiency, to thereby enhance yield of coating film. Reflection of the spray material by the outer periphery of plasma flame, penetration of the spray material through plasma flame, and scattering of the spray material caused by reflection or penetration, due to the differences in particle diameter, mass, etc. of the spray material is prevented.
    Type: Application
    Filed: June 7, 2012
    Publication date: May 29, 2014
    Applicant: SHINWA INDUSTRY CO., LTD.
    Inventor: Kenzo Toyota
  • Patent number: 8735766
    Abstract: A cathode assembly and a method for generation of pulsed plasma are disclosed. The cathode assembly comprises a cathode holder connected to multiple longitudinally aligned cathodes, preferably of the same diameter, and different lengths. The method is characterized by forming an electric arc between the cathodes in the assembly and an anode by passing DC current of a predetermined magnitude. Once the arc is established the current is reduced to the magnitude sufficient to sustain an electric arc, or a slightly larger magnitude, thereby reducing the area of arc attachment to a single cathode. Once the area of attachment has been reduced, the current is raised to the operational level of the pulse, while the area of attachment does not increase significantly.
    Type: Grant
    Filed: August 6, 2007
    Date of Patent: May 27, 2014
    Assignee: Plasma Surgical Investments Limited
    Inventor: Nikolay Suslov
  • Patent number: 8715772
    Abstract: A process for the thermal deposition coating of a workpiece is provided that comprises the steps of: thermally depositing a coating on a metallic surface of a workpiece from a deposition head wherein at least one condition selected from the group of: coating deposition rate onto said surface, relative motion between the surface and said deposition head, and cryogenic coolant application rate onto said workpiece is controllable; substantially simultaneously measuring temperatures at a plurality of locations over the metallic surface of the workpiece; determining an average temperature of the temperatures measured in step (b); comparing the average temperature to a preselected minimum temperature and a preselected maximum temperature for the workpiece; and adjusting at least one of the controllable conditions if said average temperature is not between the preselected minimum temperature and the preselected maximum temperature for the workpiece.
    Type: Grant
    Filed: March 27, 2006
    Date of Patent: May 6, 2014
    Assignee: Air Products and Chemicals, Inc.
    Inventor: Zbigniew Zurecki
  • Patent number: 8704120
    Abstract: A welding device for powder welding is described, which comprises a welding head for transportation of at least one welding electrode to a welding area, and a powder transportation device for transportation of powder from a container to the welding area. The powder transportation device comprises at least a first pipe which at a first end has an opening which is arranged to be placed in the container in order to transport fluxing agent from the container. The powder transportation device comprises at least a first ejector which is connected to the second end of the first pipe and which is arranged to transport powder from the container via the first pipe using pressurized gas.
    Type: Grant
    Filed: June 11, 2009
    Date of Patent: April 22, 2014
    Assignee: ESAB AB
    Inventors: Rolf Gösta Larsson, Björn Johansson
  • Patent number: 8692150
    Abstract: A plasma spray gun comprises a nozzle, an upstream powder injector, and a downstream powder injector. The upstream powder injector is disposed outside the nozzle and axially adjacent a nozzle outlet. The downstream powder injector is disposed axially downstream of the first upstream powder injector. The downstream powder injector is operative in a first coating mode, and the upstream powder injector is operative in a second coating mode.
    Type: Grant
    Filed: July 13, 2011
    Date of Patent: April 8, 2014
    Assignee: United Technologies Corporation
    Inventors: Christopher W. Strock, Robert D. Richard, Steven Lemay
  • Publication number: 20140061165
    Abstract: This invention relates to a method and arrangement for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by supplying the metallic feed material in the form of a wire and employing two gas transferred arcs, one plasma transferred arc for heating the deposition area on the base material and one plasma transferred arc for heating and melting the feed wire.
    Type: Application
    Filed: March 30, 2012
    Publication date: March 6, 2014
    Applicant: NORSK TITANIUM COMPONENTS AS
    Inventor: Ferdinand Stempfer
  • Publication number: 20130334176
    Abstract: A plasma spray nozzle is provided. Owing to their high degree of wear, previous plasma spray nozzles were not suitable for the coating of components for which long coating times were necessary. The coating times may be reduced considerably by the triple injection of powder into the inner channel through the plasma spray nozzle.
    Type: Application
    Filed: August 7, 2013
    Publication date: December 19, 2013
    Inventors: Mario Felkel, Heiko Gruner, Francis Ladru
  • Patent number: 8581138
    Abstract: A method of thermally depositing metal onto a target surface using a plasma transferred wire arc thermal spray apparatus, wherein the method includes the steps of offsetting the central axis of a consumable wire with respect to an axial centerline of a constricting orifice; and establishing and operating a plasma transferred wire arc between a cathode and a free end of the consumable wire; and melting and atomizing a continually fed free end of the consumable wire into molten metal particles and projecting the particles onto said target surface.
    Type: Grant
    Filed: December 22, 2011
    Date of Patent: November 12, 2013
    Assignee: Flame-Spray Industries, Inc.
    Inventors: Keith A. Kowalsky, David J. Cook, Daniel R. Marantz, John Conti
  • Patent number: 8563890
    Abstract: A method and apparatus for microplasma spray coating a portion of a turbine vane without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the turbine vane is coated with the powdered material without having to mask the turbine vane.
    Type: Grant
    Filed: December 8, 2012
    Date of Patent: October 22, 2013
    Assignee: United Technologies Corporation
    Inventors: Paul Zajchowski, Donn R. Blankenship, Gary C. Shubert, Robert L. Memmen
  • Patent number: 8450637
    Abstract: A system and method for the automated or “robotic” application of hardfacing to a surface of a drill bit.
    Type: Grant
    Filed: October 23, 2008
    Date of Patent: May 28, 2013
    Assignee: Baker Hughes Incorporated
    Inventors: David K. Luce, Alan J. Massey, Kenneth E. Gilmore, Timothy P. Uno, Keith L. Nehring
  • Patent number: 8431857
    Abstract: A process for joining a brass part and a silicone carbide ceramics part, comprising steps of: providing a metal part made of brass, a ceramic part made of silicone carbide ceramics, a titanium foil and a nickel foil; bring the metal part, ceramic part, titanium foil and nickel foil into contact, with the titanium and nickel foil inserted between the metal part and ceramic part; applying a pressure of about 20 MPa˜60 MPa to the parts to be joined; and simultaneously applying a pulse electric current to the parts while the pressure is applied for heating up the parts to a temperature of about 950° C. to about 1150° C. at a rate of about 50° C./min˜300° C./min, maintaining the temperature for about 20 minutes˜40 minutes.
    Type: Grant
    Filed: June 22, 2011
    Date of Patent: April 30, 2013
    Assignees: Hong Fu Jin Precision Industry (ShenZhen) Co., Ltd., Hon Hai Precision Industry Co., Ltd.
    Inventors: Hsin-Pei Chang, Wen-Rong Chen, Huann-Wu Chiang, Cheng-Shi Chen, Wen-Feng Hu
  • Publication number: 20130098879
    Abstract: A method and apparatus for microplasma spray coating a portion of a turbine vane without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the turbine vane is coated with the powdered material without having to mask the turbine vane.
    Type: Application
    Filed: December 8, 2012
    Publication date: April 25, 2013
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventor: UNITED TECHNOLOGIES CORPORATION
  • Publication number: 20130068729
    Abstract: A method and apparatus for microplasma spray coating a portion of a substrate, such as a gas turbine compressor blade, without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects inert gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the compressor blade is coated with the powdered material without having to mask the compressor blade.
    Type: Application
    Filed: October 31, 2012
    Publication date: March 21, 2013
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventor: United Technologies Corporation
  • Patent number: 8389888
    Abstract: The invention relates to a plasma torch, comprising: a plasma generator comprising a cathode extending along an axis X and an anode (24), the cathode and the anode being arranged so as to be capable of generating, in a chamber (26), an electric arc between the anode and the cathode due to an electrical voltage, the plasma generator also comprising a plasmagen gas injection device (30) comprising an injection pipe (72) leading, along an injection axis (Ii), to an injection opening (74) in the chamber; a means for injecting a material to be discharged into a plasma flow generated by said plasma generator, the plasma torch being characterized in that: the relationship R? between: the radial distance (yi) of said injection opening, defined as the minimum distance between the axis X and the center of said injection orifice; the largest transverse size (DC) of the cathode in the region of the chamber downstream from the position PAC, wherein PAC denotes the axial position of maximum radial mutual encroachment of th
    Type: Grant
    Filed: March 12, 2010
    Date of Patent: March 5, 2013
    Assignee: Saint-Gobain Centre de Recherches et d'Etudes Europeen
    Inventors: Alain Allimant, Dominique Billieres
  • Patent number: 8367963
    Abstract: A method and apparatus for microplasma spray coating a portion of a turbine vane without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the turbine vane is coated with the powdered material without having to mask the turbine vane.
    Type: Grant
    Filed: October 29, 2004
    Date of Patent: February 5, 2013
    Assignee: United Technologies Corporation
    Inventors: Paul H. Zajchowski, Donn Blankenship, Gary C. Shubert, Robert L. Memmen
  • Patent number: 8334476
    Abstract: A method of hard facing a metal substrate with a two-layer abrasion and impact resistant coating by fusing a softer inner first coat of a matrix alloy of nickel-, cobalt- or iron-base alloy with carbide particles onto the substrate and fusing a harder second outer coat of a matrix alloy of nickel-, cobalt- or iron-base alloy with angular carbide particles onto the softer inner first coat. The softer inner first coat preferably has a hardness of about 30-40 Rc and the harder outer second coat preferably has a hardness of about 50-60 Rc. The carbide particles preferably are tungsten carbide particles in the size range of about 60 to 250? and comprise about 55 to 65 wt % of each of the inner and outer coats.
    Type: Grant
    Filed: May 16, 2008
    Date of Patent: December 18, 2012
    Assignee: McCoy Corporation
    Inventors: Jerry McCracken, Dale M. Homeniuk
  • Patent number: 8334473
    Abstract: A method and apparatus for microplasma spray coating a portion of a substrate, such as a gas turbine compressor blade, without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects inert gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the compressor blade is coated with the powdered material without having to mask the compressor blade.
    Type: Grant
    Filed: April 22, 2010
    Date of Patent: December 18, 2012
    Assignee: United Technologies Corporation
    Inventors: Paul Zajchowski, Donn Blankenship, Gary Shubert
  • Patent number: 8258424
    Abstract: A plasma arc torch is provided that includes a wear stop designed to detect wear of an electrode and prevent the use of the electrode once the electrode has experienced a certain amount of wear. Either the electrode or the nozzle is movable with respect to the main torch body, and the movable component defines a projection. The wear stop is positioned a predetermined distance from a nozzle of the torch, such that prior to experiencing an excessive amount of wear, the electrode is able to contact the nozzle and initiate a pilot arc for starting a torch operation. Once the length of the electrode becomes shorter than a predetermined length due to wear, the projection of the electrode engages the wear stop, and the wear stop prevents the electrode from contacting the nozzle. In this way, an electrode that is excessively worn cannot be used in subsequent torch operations.
    Type: Grant
    Filed: August 20, 2009
    Date of Patent: September 4, 2012
    Assignee: The ESAB Group, Inc.
    Inventor: David C. Griffin
  • Publication number: 20120217226
    Abstract: The invention relates to a method for producing a component (10) of a turbomachine, especially a structural part of a turbine or a compressor, the method being a generative production method for the layer-by-layer buildup of the component (10). After production of one or more successive component layers pressure is applied to at least sections of the surface of the most recently produced component layer (12), the pressure being induced by laser or plasma. The invention further relates to a device for producing a component (10) of a turbomachine, especially a structural part of a turbine or a compressor, the device (26) comprising at least one powder feed (28) for the deposition of at least one powder component material (16) onto a component platform, at least one radiation source (14) for a local layer-by-layer fusion or sintering of the component material (16) and at least one laser radiation source (20) or at least one plasma impulse source.
    Type: Application
    Filed: October 30, 2010
    Publication date: August 30, 2012
    Applicant: MTU AERO ENGINES GMBH
    Inventors: Erwin Bayer, Sven-J. Hiller
  • Patent number: 8253058
    Abstract: A hybrid nozzle for use in a plasma spray gun, especially for plasma spraying silicon to form semiconductor devices such as solar cell. The outlet of the gun includes a two-piece annular electrode against which the plasma is ignited and through which the plasma plume exits the gun together with entrained silicon. In one embodiment, the upstream part is composed of graphite to allow ignition of the plasma and the downstream part is composed of pure silicon. In another aspect, the silicon feedstock is injected into the plasma plume through ports formed through the silicon part.
    Type: Grant
    Filed: March 9, 2010
    Date of Patent: August 28, 2012
    Assignee: Integrated Photovoltaics, Incorporated
    Inventor: Raanan Zehavi
  • Patent number: 8237079
    Abstract: An adjustable plasma spray gun apparatus is disclosed. In one embodiment, an adjustable plasma spray gun apparatus includes: a plasma spray gun body having a fore portion and an aft portion; and a first coupler configured to removably attach to the plasma spray gun body at the aft portion, the coupler including: a first portion having a first axial opening configured to removably attach to the plasma spray gun body at the aft portion; and a second portion having a second axial opening configured to removably attach to one of an electrode body or a second coupler.
    Type: Grant
    Filed: September 1, 2009
    Date of Patent: August 7, 2012
    Assignee: General Electric Company
    Inventors: Christopher Joseph Lochner, Joseph Garfield Albanese, Donald Joseph Baldwin, Yuk-Chiu Lau
  • Patent number: 8212182
    Abstract: A portable wire feeder for providing welding wire and welding current to a welding operation includes an input electrically connected to a power source. An output is selectively electrically connected to the input to receive welding current delivered to the input from the power source and to provide the welding current and welding wire to the welding operation through a guide hose. A contactor includes a first electrical terminal, a second electrical terminal and a conductive bridge member for selectively electrically connecting the input to the output. The first electrical terminal is electrically connected to the input. The second electrical terminal is electrically connected to the output.
    Type: Grant
    Filed: March 17, 2010
    Date of Patent: July 3, 2012
    Assignee: Lincoln Global, Inc.
    Inventor: Nicholas G. Mormino, Jr.
  • Patent number: 8212174
    Abstract: A casing is used for being rotatably disposed in a plasma jet system. The casing is rotated around a central axis. The casing comprises a main body and a plasma nozzle. The main body has a first cavity. The plasma nozzle is disposed under the main body and has a second cavity and a straight channel. The second cavity is connected to the first cavity. The straight channel is located at a side of the plasma nozzle opposite to the main body and connected to the second cavity. The straight channel has an extension axis which is substantially parallel with the central axis and separated from the central axis by an interval. Plasma generated by the plasma jet system jets out through the straight channel.
    Type: Grant
    Filed: August 7, 2009
    Date of Patent: July 3, 2012
    Assignee: Industrial Technology Research Institute
    Inventors: Chen-Der Tsai, Wen-Tung Hsu, Chin-Jyi Wu, Chih-Wei Chen
  • Patent number: 8203103
    Abstract: In an embodiment an apparatus for coating a substrate comprises: an array of plasma arcs; a first plurality of reagent manifolds located upstream of the array of plasma arcs and a second plurality of reagent manifolds located downstream of the array of plasma arcs, each manifold having at least one orifice through which a reagent is ejected into a plasma jet issuing from a respective plasma arc; and a controller which modulates the flow of reagent to each manifold according to the contours of the substrate and to the substrate position relative to the plasma arcs and the manifolds.
    Type: Grant
    Filed: March 15, 2011
    Date of Patent: June 19, 2012
    Assignee: Exatec LLC
    Inventor: Steven M. Gasworth
  • Patent number: 8203095
    Abstract: A method of material treatment in which the surface of a metal substrate is converted to a composite structure of the metal and its nitride or carbide utilizing a high temperature chemically active thermal plasma stream, and the product obtained from that method. The complex thermal plasma contains controllable additions of active gas, liquid or solid substances. The surface layer obtained is functionally graded to the substrate resulting in an excellent bond that resists delamination and spalling, and provides a significant increase in hardness, wear and erosion resistance, and corrosion resistance, and a decrease in coefficient of friction.
    Type: Grant
    Filed: April 16, 2007
    Date of Patent: June 19, 2012
    Assignee: Materials & Electrochemical Research Corp.
    Inventors: Roger S. Storm, Vladimir Shapovalov, James C. Withers, Raouf Loutfy
  • Patent number: 8158906
    Abstract: Conventional welding methods have the disadvantage of producing worse welded joints at the beginning of the process than in the later course of the method. The method in question uses an initializing plate on which the welding process is begun and then once a consistent quality can be achieved for the welded joint continues onto the points for repair.
    Type: Grant
    Filed: November 30, 2006
    Date of Patent: April 17, 2012
    Assignee: Siemens Aktiengesellschaft
    Inventors: Francis-Jurjen Ladru, Gerhard Reich, Helge Reymann
  • Publication number: 20120024824
    Abstract: The interior of a straight pipe is clad using a plurality of welding heads. The pipe is carried on support rollers including drive components for rotating the pipe about its axis while holding it fixed against axial movement. There are four welding heads with two carried on a cantilevered support arm of a respective one of a first and a second carriage mounted outside the pipe at opposite ends of the pipe and each movable in a direction longitudinally of the axis of the pipe. The heads are located on the arm at a common angular position at bottom dead center to weld vertically downwardly. The pipe support includes a pair of drive rollers arranged with their axes parallel to the axis of the pipe and adjustable in spacing to change the height of the pipe on the rollers relative to the welding heads.
    Type: Application
    Filed: July 28, 2010
    Publication date: February 2, 2012
    Inventor: Randel Brandstrom
  • Publication number: 20120018407
    Abstract: In one or more embodiments, the invention relates to a plasma transfer wire arc thermal spray system, comprising a section for feeding a wire acting as a first electrode, a source of plasma gas providing plasma gas, a nozzle directing the plasma gas stream from the source of plasma gas to a free end of the wire, and a second electrode located in the plasma gas stream towards the nozzle. In certain instances, the nozzle is made at least partially of electrically insulating material. The thermal spray apparatus with the inventive spray gun may have a simplified and faster starting procedure and the spray nozzle can be more durable.
    Type: Application
    Filed: March 31, 2010
    Publication date: January 26, 2012
    Applicant: FORD GLOBAL TECHNOLOGIES, LLC
    Inventors: Leander Schramm, Alexander Schwenk, Enrico Hauser
  • Patent number: 8070042
    Abstract: A process for joining a stainless steel part and a silicon carbide ceramic part, comprising steps of: providing a stainless steel part, a SiC ceramic part, and a Al foil; bringing surfaces of the stainless steel part, SiC ceramic part, and Al foil into contact, with the titanium foil inserted between the metal part and ceramic part; applying a pulsed electric current to the stainless steel part, SiC ceramic part, and Al foil, heating the stainless steel part, SiC ceramic part, and Al foil to a joining temperature of about 500-650° C., and simultaneously applying a joining pressure of about 50-100 MPa to the stainless steel part, SiC ceramic part, and Al foil while the current is applied, and maintaining the joining temperature and the joining pressure for about 10-30 minutes.
    Type: Grant
    Filed: June 28, 2011
    Date of Patent: December 6, 2011
    Assignees: Hong Fu Jin Precision Industry (ShenZhen) Co., Ltd., Hon Hai Precision Industry Co., Ltd.
    Inventors: Hsin-Pei Chang, Wen-Rong Chen, Huann-Wu Chiang, Cheng-Shi Chen, Wen-Feng Hu
  • Patent number: 8067711
    Abstract: Microspray apparatus and methods involve injecting powdered material into a plasma gas stream. The material comprises first and second component powders. The second powder is a majority by the weight of the powdered material. The first powder acts as a melting point depressant. The first and second powders may have similar compositions but with the first powder including a greater quantity of a melting point depressant element.
    Type: Grant
    Filed: July 14, 2005
    Date of Patent: November 29, 2011
    Assignee: United Technologies Corporation
    Inventors: Donn R. Blankenship, David A. Rutz, Norman A. Pietruska, Paul H. Zajchowski, Gary Shubert
  • Patent number: 8030592
    Abstract: A plasma spray apparatus in the form of a gun is utilized to apply an antifoulant coating to marine vessels. The apparatus includes a plasma generator, an electrophoresis element, a heating element, a shield gas element, a liquid cooling system, a forced air system, and a vacuum system. The plasma generator ionizes gas to create a plasma stream, which is utilized in part to supply energy to the heating element that heats a powder material. The heated powder material is exposed to the electrophoresis element to create a covalently bonded coating material. The coating material is injected into the plasma stream and is applied to a target surface. The shield gas element injects a gas flow to surround and protect the plasma and coating material stream as the stream is in flight to the target surface. The liquid cooling system cools portions of the plasma generator and heating element. The forced air system cools a portion of the target surface as the coating material is being applied.
    Type: Grant
    Filed: June 6, 2007
    Date of Patent: October 4, 2011
    Assignee: Reintjes Marine Surface Technologies, LLC
    Inventor: Larry Weidman
  • Patent number: 7952047
    Abstract: An improved automatic feedback control scheme enhances plasma spraying of powdered material through reduction of process variability and providing better ability to engineer coating structure. The present inventors discovered that controlling centroid position of the spatial distribution along with other output parameters, such as particle temperature, particle velocity, and molten mass flux rate, vastly increases control over the sprayed coating structure, including vertical and horizontal cracks, voids, and porosity. It also allows improved control over graded layers or compositionally varying layers of material, reduces variations, including variation in coating thickness, and allows increasing deposition rate. Various measurement and system control schemes are provided.
    Type: Grant
    Filed: August 8, 2005
    Date of Patent: May 31, 2011
    Assignee: Cyber Materials LLC
    Inventors: Michael Alan Gevelber, Donald Edward Wroblewski
  • Patent number: 7928338
    Abstract: A device and a method for plasma spraying are disclosed. The device comprises, a cathode, an anode, a plasma channel formed by the anode and intermediate electrodes, and one or more flowable material injectors. The plasma channel has a throttling portion that divides the plasma channel into a high pressure portion near the cathode formed by at least one intermediate electrode and a low pressure portion near the anode. During operation, a plasma generating gas is heated by the arc maintained between the cathode and the anode, forming plasma. When the plasma passes through the throttling portion, its speed increases to a supersonic speed, and at the same time its static pressure drops. Flowable materials are injected in the plasma flow in the low pressure portion. The particles in the flowable materials are heated by the plasma and the resultant heated particles and plasma are output from the outlet of the plasma channel.
    Type: Grant
    Filed: February 2, 2007
    Date of Patent: April 19, 2011
    Assignee: Plasma Surgical Investments Ltd.
    Inventor: Nikolay Suslov
  • Patent number: 7892609
    Abstract: The invention relates to a thermal spraying apparatus (1) for coating a surface (2) of a substrate (3) by means of a coating material (4). The thermal spraying apparatus (1) includes a spray pistol (5) with a heating device for heating the coating material (4) in a heating zone (6) and also a charging apparatus (7) with a feed (8) through which the coating material (4) can be introduced into the heating zone (6). In this arrangement the thermal spraying apparatus is so designed that a relative position (9) between the feed (8) and the heating zone (6) can be changed in the operating state.
    Type: Grant
    Filed: October 18, 2005
    Date of Patent: February 22, 2011
    Assignee: Sulzer Metco AG
    Inventor: Markus Mueller