Metco, Inc.

Herbert S Ingham, Jr

Ferdinand J Dittrich

Arthur J Fabel

George J Durmann

A flame spraying device including a rocket accelerator wherein a low velocity flame is produced into which a coating material is introduced. At least one rocket accelerator producing a high velocity stream of combustion product gases is positioned relative to the low velocity flame so that the coating material carried thereby is accelerated toward the substrate to be coated. By positioning the rocket relative to the low velocity flame, the dwell time in the low velocity flame can be optimized to produce the best coating of a substrate. The coating quality is also enhanced by the fact that the coating material does not oxidize or cool significantly while in the high velocity stream and by the fact that the coating material strikes the substrate at high speed thereby resulting in high density coating.

Flame spraying device with rocket acceleration

A flame spray material in the form of a composite comprising (1) as a first component an alloy containing at least about 40% of its weight of at least one of nickel and cobalt, and about 1 to 6% by weight of boron, and (2) aluminum powder as a second component, the first component being present in about 66 to 99% by weight of the composite. The material, desirably blended with about 10% of an aluminum-molybdenum-coated nickel core powder, produces self-bonded wear resistant coatings which can be ground without cracking.

Aluminum-coated nickel or cobalt core flame spray materials

An improvement in a process for high velocity plasma flame-spraying of a powder onto a workpiece wherein an unlit plasma gas is passed through the nozzle of a plasma flame-spraying gun at a high velocity of at least 90 meters per second and an electric arc is struck between an electrode within said gun and a portion of said nozzle and powder is fed into the resultant flame exteriorly of said nozzle and said gun, which improvement comprises increasing the deposit efficiency of the coating of the powder onto the workpiece by carrying out said process such that the power through said electric arc is at least 15 kilowatts, disposing the arc created at the exit rim of said nozzle by regulating the gas velocity, length of nozzle and diameter of nozzle bore such that said arc is established at said exit rim of said nozzle, especially a process wherein a gas back pressure is maintained within said nozzle which is greater than 1 atmosphere gauge, the ignited plasma gas has an enthalpy of at least 7000 joules/standard liter of gas such that there are created zones of compression and rarefaction coterminously in the resultant flame and the powder is introduced into the zones of rarefaction; an apparatus for carrying out such a process.

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Northport, NY, United States of America

Herbert S Ingham, Jr