Eutectic Corporation

Eduardo Romero

Anthony J Rotolico

John E Lyons

Richard J DuMola

Richard J Dumola

A blended flame spray powder composition is provided for use in producing a bonded wear resistant coating on an aluminum bronze substrate such as a glass mold part. The blended composition comprises a copper-base alloy mixed with a nickel-base alloy, the copper-base alloy powder comprising by weight about 5% to 15% aluminum, about 5% to 30% nickel, 0 to about 1% iron, about 0.1 to 1% silicon and the balance essentially copper. The nickel-base alloy powder comprises by weight 0 to about 0.5% carbon, 0 to about 1% manganese, 0 to about 21.5% chromium, 0 to about 7.5% iron, 0 to about 3.75% columbium, about 0.5% to 3% silicon, 0 to about 9% molybdenum, 0 to about 2% boron, 0 to about 2.5% phosphorus and the balance essentially nickel. The blending ratio of one powder to the other is such that a bonded coating produced therefrom on an aluminum bronze substrate, such as a glass mold part, contains at least about 9% copper and at least about 1.25% aluminum.

Alloy coating for aluminum bronze parts, such as molds

A method for producing a weld-bonded nickel-base alloy coating on a cast iron part with minimum porosity at the weld interface is provided using a plasma transferred arc process in which the cast iron part is electrically coupled to the plasma-forming circuit, the flow of powder being directed into the plasma arc to the surface of the cast iron part. The method further resides in controlling the deposit of the nickel-base alloy during spraying to maintain a puddle of the alloy between the transfer arc plasma and the cast iron part substrate to protect it from overheating and burning from the transfer arc while promoting a welding reaction between the puddle and the cast iron substrate. The plasma spraying is continued progressively along the cast iron substrate to be coated while maintaining the alloy puddle between the plasma arc and the cast iron until completion of the coating thereof. The invention also relates to a composite article of manufacture.

Alloy coating for cast iron parts, such as glass molds

The invention contemplates a powder-feeding system for gas-propelled delivery of a powder to be controllably supplied, as to a flame-spraying gas torch or to a transferred-arc plasma torch. A fluidizing chamber receives (a) fluidizing-gas flow from below a porous screen, and (b) a restricted gravitational flow of powder at a relatively small central discharge location above the porous screen. A gas conduit extends transversely through the chamber between the powder-discharge location and the porous screen; it has a carrier-gas supply connection at one end and a gas-propelled powder-delivery connection at its other end. The conduit also has an upwardly extending opening virtually beneath and facing the powder-discharge location, but a shed interposed between this opening and the powder-discharge location sufficiently overlaps the opening to assure that no powder will pass through the opening and into the conduit unless it has been gas-fluidized. The powder-discharge flow is blocked to gas flow when powder is being delivered by the carrier-gas flow, but the powder delivery is terminated promptly upon gas-venting the fluidizing chamber, via the powder-discharge flow or otherwise. A multiple-unit combination of such a system is also described wherein the proportion of different gas-fluidized powders may be selectively varied and/or coordinated to achieve various different application objectives, as in the course of a single run of a flame-spraying torch served by such combination.

Device for the controlled feeding of powder material

The invention contemplates a plasma-transferred-arc torch construction wherein, optionally, a single releasable clamp enables rapid separation of downstream-end fittings of an anode subassembly and a cathode subassembly, as for inspection, servicing and/or replacement; in an alternative option, release of the single clamp enables rapid further disassembly of the entirety of the respective subassemblies from mounting structure which includes the single clamp. These options are available for torch structure incorporating provision for sealed independent fluid-flow supplies of (a) coolant serving both electrode subassemblies, (b) plasma gas serving an annular interelectrode gap at the downstream end of the torch, (c) a metallic, ceramic or other powder fluidized in a carrier gas, for torch-deposition of the powder, and (d) a shielding gas to protect the zone of plasma-transfer of the arc and any powder conveyed therewith.

Plasma-transferred-arc torch construction

The invention contemplates a powder-feeding system for gas-propelled delivery of a powder to be controllably supplied, as to a flame-spraying gas torch or to a transferred-arc plasma torch. A fluidizing chamber receives (a) fluidizing-gas flow from below a porous screen, and (b) a restricted gravitational flow of powder at a relatively small central discharge location above the porous screen. A gas conduit extends transversely through the chamber between the powder-discharge location and the porous screen; it has a carrier-gas supply connection at one end and a gas-propelled powder-delivery connection at its other end. The conduit also has an upwardly extending opening virtually beneath and facing the powder-discharge location, but a shed interposed between this opening and the powder-discharge location sufficiently overlaps the opening to assure that no powder will pass through the opening and into the conduit unless it has been gas-fluidized. The powder-discharge flow is blocked to gas flow when powder is being delivered by the carrier-gas flow, but the powder delivery is terminated promptly upon gas-venting the fluidizing chamber, via the powder-discharge flow or otherwise.

The invention contemplates an elongate extension nozzle attachment for a gas torch whereby flame-spraying of coating-powder material may be applied with precision to the bore of a workpiece. The attachment is detachably securable to conventional torch and/or gas-distributor structure and provides independent flows of (a) carrier gas and powder and (b) combustible-gas mixture to a nozzle which is removably fitted to the discharge end. Provision is made for optional use of one or more flame-shaping discharges of air, inert gas or the like at the discharge end, using a further independent supply system within the attachment.

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Coram, NY, United States of America

Eduardo Romero