Plasma Patents (Class 219/76.16)
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Patent number: 11920217Abstract: 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: GrantFiled: August 31, 2018Date of Patent: March 5, 2024Assignees: The Boeing Company, VSMPO-AVISMA CorporationInventors: Natalia Mitropolskaya, Robert Briggs, Catherine Parrish, Arash Ghabchi, Matthew Crill, Michael Leder, Igor Puzakov, Alexey Zaitsev, Natalia Tarenkova
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Patent number: 11773491Abstract: 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: GrantFiled: January 21, 2021Date of Patent: October 3, 2023Assignee: UNIVERSITIES SPACE RESEARCH ASSOCIATIONInventors: Ramprasad Gandhiraman, Meyya Meyyappan, Jessica E. Koehne
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Patent number: 10995406Abstract: 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: GrantFiled: April 3, 2017Date of Patent: May 4, 2021Assignee: UNIVERSITIES SPACE RESEARCH ASSOCIATIONInventors: Ramprasad Gandhiraman, Meyya Meyyappan, Jessica E. Koehne
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Patent number: 10738374Abstract: 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: GrantFiled: January 4, 2017Date of Patent: August 11, 2020Assignee: TOKYO ELECTRON LIMITEDInventors: Shinya Okabe, Hideaki Yamasaki, Junya Oka, Yuuji Kobayashi, Takamichi Kikuchi
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Patent number: 10071387Abstract: 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: GrantFiled: September 4, 2012Date of Patent: September 11, 2018Assignee: IMAGINEERING, INC.Inventor: Yuji Ikeda
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Patent number: 9896760Abstract: 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: GrantFiled: November 4, 2015Date of Patent: February 20, 2018Assignee: CANON ANELVA CORPORATIONInventors: Hidekazu Nishimura, Naoyuki Nozawa
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Patent number: 9630162Abstract: 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: GrantFiled: April 4, 2012Date of Patent: April 25, 2017Assignee: University of Louisville Research Foundation, Inc.Inventors: Mahendra Kumar Sunkara, Jeong H. Kim, Vivekanand Kumar
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Patent number: 9548591Abstract: 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: GrantFiled: January 28, 2016Date of Patent: January 17, 2017Assignee: Fram Group IP LLCInventors: Jing Zheng, Jeffrey T. Boehler, Prabhu Megharaj, Philip Treier
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Patent number: 9457517Abstract: 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: GrantFiled: December 20, 2013Date of Patent: October 4, 2016Assignee: INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTEInventors: Chung-Wei Cheng, Kuang-Po Chang, Cen-Ying Lin, Shu-Yi Wang
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Patent number: 9024230Abstract: 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: GrantFiled: April 13, 2012Date of Patent: May 5, 2015Assignee: Victor Equipment CompanyInventors: Daniel Wayne Barnett, Nakhleh Hussary
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Publication number: 20150060413Abstract: 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: ApplicationFiled: September 4, 2014Publication date: March 5, 2015Applicant: MAHLE INDUSTRIES, INC.Inventor: Thomas SMITH
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Publication number: 20140360788Abstract: 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: ApplicationFiled: June 10, 2013Publication date: December 11, 2014Inventors: MICHEL JUNOD, Michael Gill, Alain Tremblay
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Patent number: 8847098Abstract: 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: GrantFiled: July 22, 2010Date of Patent: September 30, 2014Assignee: Thermal Structures, Inc.Inventor: Vaughn V. Barnes
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Patent number: 8822874Abstract: 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: GrantFiled: October 31, 2012Date of Patent: September 2, 2014Assignee: United Technologies CorporationInventors: Paul Zajchowski, Donn Blankenship, Gary C. Shubert
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Patent number: 8803025Abstract: 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: GrantFiled: December 10, 2010Date of Patent: August 12, 2014Assignee: SDCmaterials, Inc.Inventors: Frederick P. Layman, David Leamon
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Publication number: 20140166625Abstract: 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: ApplicationFiled: December 17, 2012Publication date: June 19, 2014Applicants: FUJI ENGINEERING CO., LTD., WEST NIPPON EXPRESSWAY COMPANY LIMITED, FUJIGIKEN CO., LTD.Inventors: Masanobu SUGIMOTO, Kenichi YAMADA, Masanobu IRIE
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Publication number: 20140144888Abstract: 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: ApplicationFiled: June 7, 2012Publication date: May 29, 2014Applicant: SHINWA INDUSTRY CO., LTD.Inventor: Kenzo Toyota
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Patent number: 8735766Abstract: 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: GrantFiled: August 6, 2007Date of Patent: May 27, 2014Assignee: Plasma Surgical Investments LimitedInventor: Nikolay Suslov
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Patent number: 8715772Abstract: 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: GrantFiled: March 27, 2006Date of Patent: May 6, 2014Assignee: Air Products and Chemicals, Inc.Inventor: Zbigniew Zurecki
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Patent number: 8704120Abstract: 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: GrantFiled: June 11, 2009Date of Patent: April 22, 2014Assignee: ESAB ABInventors: Rolf Gösta Larsson, Björn Johansson
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Patent number: 8692150Abstract: 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: GrantFiled: July 13, 2011Date of Patent: April 8, 2014Assignee: United Technologies CorporationInventors: Christopher W. Strock, Robert D. Richard, Steven Lemay
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Publication number: 20140061165Abstract: 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: ApplicationFiled: March 30, 2012Publication date: March 6, 2014Applicant: NORSK TITANIUM COMPONENTS ASInventor: Ferdinand Stempfer
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Publication number: 20130334176Abstract: 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: ApplicationFiled: August 7, 2013Publication date: December 19, 2013Inventors: Mario Felkel, Heiko Gruner, Francis Ladru
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Patent number: 8581138Abstract: 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: GrantFiled: December 22, 2011Date of Patent: November 12, 2013Assignee: Flame-Spray Industries, Inc.Inventors: Keith A. Kowalsky, David J. Cook, Daniel R. Marantz, John Conti
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Patent number: 8563890Abstract: 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: GrantFiled: December 8, 2012Date of Patent: October 22, 2013Assignee: United Technologies CorporationInventors: Paul Zajchowski, Donn R. Blankenship, Gary C. Shubert, Robert L. Memmen
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Patent number: 8450637Abstract: A system and method for the automated or “robotic” application of hardfacing to a surface of a drill bit.Type: GrantFiled: October 23, 2008Date of Patent: May 28, 2013Assignee: Baker Hughes IncorporatedInventors: David K. Luce, Alan J. Massey, Kenneth E. Gilmore, Timothy P. Uno, Keith L. Nehring
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Patent number: 8431857Abstract: 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: GrantFiled: June 22, 2011Date of Patent: April 30, 2013Assignees: 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
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Publication number: 20130098879Abstract: 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: ApplicationFiled: December 8, 2012Publication date: April 25, 2013Applicant: UNITED TECHNOLOGIES CORPORATIONInventor: UNITED TECHNOLOGIES CORPORATION
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Publication number: 20130068729Abstract: 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: ApplicationFiled: October 31, 2012Publication date: March 21, 2013Applicant: UNITED TECHNOLOGIES CORPORATIONInventor: United Technologies Corporation
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Patent number: 8389888Abstract: 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 thType: GrantFiled: March 12, 2010Date of Patent: March 5, 2013Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Alain Allimant, Dominique Billieres
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Patent number: 8367963Abstract: 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: GrantFiled: October 29, 2004Date of Patent: February 5, 2013Assignee: United Technologies CorporationInventors: Paul H. Zajchowski, Donn Blankenship, Gary C. Shubert, Robert L. Memmen
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Patent number: 8334476Abstract: 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: GrantFiled: May 16, 2008Date of Patent: December 18, 2012Assignee: McCoy CorporationInventors: Jerry McCracken, Dale M. Homeniuk
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Patent number: 8334473Abstract: 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: GrantFiled: April 22, 2010Date of Patent: December 18, 2012Assignee: United Technologies CorporationInventors: Paul Zajchowski, Donn Blankenship, Gary Shubert
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Patent number: 8258424Abstract: 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: GrantFiled: August 20, 2009Date of Patent: September 4, 2012Assignee: The ESAB Group, Inc.Inventor: David C. Griffin
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Publication number: 20120217226Abstract: 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: ApplicationFiled: October 30, 2010Publication date: August 30, 2012Applicant: MTU AERO ENGINES GMBHInventors: Erwin Bayer, Sven-J. Hiller
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Patent number: 8253058Abstract: 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: GrantFiled: March 9, 2010Date of Patent: August 28, 2012Assignee: Integrated Photovoltaics, IncorporatedInventor: Raanan Zehavi
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Patent number: 8237079Abstract: 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: GrantFiled: September 1, 2009Date of Patent: August 7, 2012Assignee: General Electric CompanyInventors: Christopher Joseph Lochner, Joseph Garfield Albanese, Donald Joseph Baldwin, Yuk-Chiu Lau
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Patent number: 8212174Abstract: 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: GrantFiled: August 7, 2009Date of Patent: July 3, 2012Assignee: Industrial Technology Research InstituteInventors: Chen-Der Tsai, Wen-Tung Hsu, Chin-Jyi Wu, Chih-Wei Chen
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Patent number: 8212182Abstract: 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: GrantFiled: March 17, 2010Date of Patent: July 3, 2012Assignee: Lincoln Global, Inc.Inventor: Nicholas G. Mormino, Jr.
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Patent number: 8203095Abstract: 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: GrantFiled: April 16, 2007Date of Patent: June 19, 2012Assignee: Materials & Electrochemical Research Corp.Inventors: Roger S. Storm, Vladimir Shapovalov, James C. Withers, Raouf Loutfy
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Patent number: 8203103Abstract: 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: GrantFiled: March 15, 2011Date of Patent: June 19, 2012Assignee: Exatec LLCInventor: Steven M. Gasworth
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Patent number: 8158906Abstract: 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: GrantFiled: November 30, 2006Date of Patent: April 17, 2012Assignee: Siemens AktiengesellschaftInventors: Francis-Jurjen Ladru, Gerhard Reich, Helge Reymann
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Publication number: 20120024824Abstract: 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: ApplicationFiled: July 28, 2010Publication date: February 2, 2012Inventor: Randel Brandstrom
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Publication number: 20120018407Abstract: 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: ApplicationFiled: March 31, 2010Publication date: January 26, 2012Applicant: FORD GLOBAL TECHNOLOGIES, LLCInventors: Leander Schramm, Alexander Schwenk, Enrico Hauser
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Patent number: 8070042Abstract: 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: GrantFiled: June 28, 2011Date of Patent: December 6, 2011Assignees: 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
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Patent number: 8067711Abstract: 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: GrantFiled: July 14, 2005Date of Patent: November 29, 2011Assignee: United Technologies CorporationInventors: Donn R. Blankenship, David A. Rutz, Norman A. Pietruska, Paul H. Zajchowski, Gary Shubert
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Patent number: 8030592Abstract: 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: GrantFiled: June 6, 2007Date of Patent: October 4, 2011Assignee: Reintjes Marine Surface Technologies, LLCInventor: Larry Weidman
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Patent number: 7952047Abstract: 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: GrantFiled: August 8, 2005Date of Patent: May 31, 2011Assignee: Cyber Materials LLCInventors: Michael Alan Gevelber, Donald Edward Wroblewski
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Patent number: 7928338Abstract: 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: GrantFiled: February 2, 2007Date of Patent: April 19, 2011Assignee: Plasma Surgical Investments Ltd.Inventor: Nikolay Suslov
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Patent number: 7892609Abstract: 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: GrantFiled: October 18, 2005Date of Patent: February 22, 2011Assignee: Sulzer Metco AGInventor: Markus Mueller