Abstract: An apparatus and method for spraying molten metal that is light weight, requires low maintenance and is quick and simple to operate. A feed system is provided that uses an electric motor and control system to push the electrodes to the head and to prevent system failure, by temporarily stopping the feed, upon the occurrence of the feed wires becoming shorted or welded together. A portable head is provided that employs parallel lead guides that allows complete head manipulation without electrode mismatch. An atomizing gas nozzle is also provided that permits lower air pressure and compensates for arc wander. A lead system is provided that combines into one lead the feed wire guides, current leads and the atomizing gas. The atomizing gas also becomes a coolant allowing lighter current leads for arc metal spraying.

Abstract: Within ultra high velocity flame spray apparatus, the oxy-fuel products of combustion under pressure exit from an internal burner and pass through a spray nozzle of extended length. Metal or ceramic material in thin diameter rod form or as particles are fed to the nozzle inlet at a point at or just ahead of the throat of the nozzle bore. The exceptionally long nozzle flow path and the mode of introduction of the material into the flame spray insures a concentrated and highly focussed core of spray material for material spray coating downstream of the nozzle at supersonic speed.

Abstract: A spraying gun for spraying molten metals consisting of a housing, a heatable container for the material to be sprayed, an adjustable spraying nozzle, a handle and actuating rods to open and close inlets for pressurized air and heating gas in which the gas heated container is provided within the housing in a manner that the end of the container is located within a burning chamber adjacent to the end of the gas burner. The housing is thermally isolated from the handle with the actuating lever preferably by silicone rubber or polytetrafluoroethylene layers. The spraying nozzle is regulated by a needle valve which is adjusted by a micrometer screw.

Abstract: A high velocity gaseous accelerating secondary jet stream in the form of the products of combustion of an internal burner is directed as a converging annular flow about and into a primary jet stream of high temperature bearing melted particles to accelerate the particles for improved impingement coating of a substrate with the internal burner operated under parameters such that the secondary jet stream is at sufficiently high temperature to prevent solidification of the particles during transport by the higher molten secondary stream prior to impact on the substrate surface.

Abstract: Apparatus for a wire spray coating method including a capacitor connected with an electric power source to be charged thereby. A gap switch having discharge electrodes which are spaced apart from each other so that a discharge is produced under a voltage applied by the capacitor. Wire receiving terminals which are spaced apart to receive a length of wire of coating material therebetween, the terminals being connected with the capacitor so that the charge of the capacitor is applied to the terminals through the switch. The discharge electrodes being maintained at a fixed distance so that a discharge across the electrodes is readily produced when the electrodes are supplied with the voltage from the capacitor.

Abstract: A flame spraying material consisting of a wire obtained by compacting zinc powder, zinc-aluminum alloy powder or admixed powders of zinc and aluminum or consisting of a composite wire obtained by enclosing said compacted powders in an aluminum covering.

Abstract: An arc spray gun has a high pressure air nozzle. To the front of the air nozzle are two wire guides. A suitable metallic wire extends through each metallic guide. An electrical potential is placed through each wire within the nozzle wire guide. As the wire is heated by the electrical potential beyond its melting point, high pressure air is ejected from the air nozzle, atomizes the metal wire, and blows a metallic spray forward. A nozzle housing is within the path of the spray. The nozzle housing has two frusto-conical sleeves coaligned to direct the flow of the metal spray. An orifice plate is positioned in the path of the metal spray. The orifice plate has a plurality of fine apertures extending through another portion thereof, and in its center portion has a plurality of larger apertures extending therethrough. The atomized metallic spray passes through the two sleeves and the orifice plate.