Flame Spray Industries, Inc.

Ford Global Technolgoies, LLC

Other

Ford Motor Company Limited

F. W. Gartner Thermal Spraying, Ltd.

Keith Alan Kowalsky

Daniel R Marantz

David James Cook

David J Cook

James R Baughman

David R Marantz

John Conti

Thomas Hubert Van Steenkiste

John Robert Smith

David D Barton

Larry Gerald Gargol

Chris Berghorn

Scott R Harrigan

James A Gourash

David R Cook

Raymond M Schneider

Christopher R Berghorn

A system (), apparatus (), and method () for creating a particle stream () that is deflected with a secondary gas () such as air before coming into contact with the treated substrate surface (). The system () can be implemented as an improvement to a prior art PTWA (plasma transferred wire arc) thermal spraying apparatus () by using a non-symmetrical passageway configuration (). Such a configuration can be an attribute of a nozzle () or a secondary gas director () such as an air baffle ().

System, apparatus, and method for deflected thermal spraying

A system (), apparatus (), and method () for monitored thermal spraying. One or more sensors () are used to capture one or more types of measurements () to monitor the thermal spraying process. A processor () can analyze a waveform () of measurements (), such as electrical measurements (). The processor () can then initiate a response () such as a warning () or an automatic adjustment () that is triggered by an identified operating condition ().

System, apparatus, and method for monitored thermal spraying

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.

Thermal spray method and apparatus using plasma transferred wire arc

A feeder apparatus supplies a powder feedstock to a high or low pressure processing operation. The apparatus includes a metering plate defining an annular channel having a channel width. A measuring mechanism dispenses a measured volume of the feedstock into the annular channel. The measuring mechanism includes a pay-out device defining an outlet significantly smaller than the channel width. The measuring mechanism further includes a maximum fill level defining a maximum pressure head in the feedstock less than a retaining pressure defined by the internal friction of the feedstock. The restraining pressure prevents the feedstock from spreading outwardly in the annular channel and contacting sidewalls of the annular channel under the pressure head of the feedstock. The apparatus further includes a pick-up device for removing the feedstock from the annular channel. The pick-up device includes an inlet having a rectangular shape extending across the annular channel.

Feeder apparatus for controlled supply of feedstock

A plasma spray apparatus for applying a coating to an article, wherein the apparatus includes a cup shaped plasma nozzle and a main gas nozzle coaxially surrounding the exterior of the plasma nozzle forming a passage between the main gas nozzle and the plasma nozzle through which the main gas containing powder particles is caused to coaxially flow, and a converging/diverging nozzle positioned at the exit of the plasma nozzle and main gas nozzle, having an entry chamber into which the plasma gas and the main gas with powder particles entrained therein flow and combine to establish a gas mixture, the gas mixture accelerating through the extended bore of the converging/diverging nozzle to a sonic or supersonic velocity so that upon impact onto the surface of the article a cohesively bonded coating will form and build-up.

Plasma spray apparatus for applying a coating utilizing particle kinetics

A method of operation of a plasma torch and the plasma apparatus to produce a hot gas jet stream directed towards a workpiece to be coated by first injecting a cold high pressure carrier gas containing a powder material into a cold main high pressure gas flow and then directing this combined high pressure gas flow coaxially around a plasma exiting from an operating plasma generator and converging directly into the hot plasma effluent, thereby mixing with the hot plasma effluent to form a gas stream with a net temperature based on the enthalpy of the plasma stream and the temperature and volume of the cold high pressure converging gas, establishing a net temperature of the gas stream at a temperature such that the powdered material will not melt or soften, and projecting the powder particles at high velocity onto a workpiece surface. The improvement resides in mixing a cold high pressure carrier gas with powder material entrained in it, with a cold high pressure gas flow of gas prior to mixing this combined gas flow with the plasma effluent which is utilized to heat the combined gas flow to an elevated temperature limited to not exceeding the softening point or melting point of the powder material. The resulting hot high pressure gas flow is directed through a supersonic nozzle to accelerate this heated gas flow to supersonic velocities, thereby providing sufficient velocity to the particles striking the workpiece to achieve a kinetic energy transformation into elastic deformation of the particles as they impact the onto the workpiece surface and forming a dense, tightly adhering cohesive coating. Preferably the powder material is of metals, alloys, polymers and mixtures thereof or with semiconductors or ceramics and the powder material is preferably of a particle size range exceeding 50 microns. The system also includes a rotating member for coating concave surfaces and internal bores or other such devices which can be better coated using rotation.

Rotary plasma spray method and apparatus for applying a coating utilizing particle kinetics

A method of operation of a plasma torch. A cold high pressure carrier gas containing a powder material is injected into a cold main high pressure gas flow and then this combined flow is directed coaxially around a plasma exiting from an operating plasma generator and converging into the hot plasma effluent, mixing with the effluent to form a gas stream with a net temperature, based on the enthalpy of the plasma stream and the temperature and volume of the cold high pressure converging gas, such that the powdered material will not melt. The combined flow with entrained is directed through a supersonic nozzle accelerating the flow to supersonic velocites sufficient that the particles striking the workpiece achieve kinetic energy transformation into elastic deformation of the particles as they impact the workpiece forming a cohesive coating.

Plasma spray method for applying a coating utilizing particle kinetics

A feedstock feeder for supplying feedstock to a system operating at a level of pressure. The feedstock feeder includes a pressure vessel having a pressure which is higher than the level of pressure; a mechanical feeder portion which meters the flow of feedstock to the system, the mechanical feeder portion located within the pressure vessel; a feedstock supplier which supplies feedstock to the mechanical feeder portion, the feedstock supplier located within the pressure vessel; a drive mechanism for driving a dynamically moving portion attached to the drive mechanism, the dynamically moving portion coupled to the mechanical feeder portion for moving the mechanical feeder portion; and wherein all dynamic seals operating to seal about the dynamically moving portion are positioned within the pressure vessel.

Method and apparatus for the controlled supply of feedstock to a feedstock processing facility operating at high pressure

Method of thermally depositing metal at increased rates onto a target surface, comprising: establishing and operating a high velocity plasma transferred wire arc between a cathode and the free-end of a consumable wire electrode, the energy of such plasma and arc being sufficient to not only melt and atomize the free-end of the wire into metal particles, but also project the particles as a column onto the target surface at an enhanced deposition rate for continuous periods in excess of 50 hours; surrounding the plasma and arc with high velocity and high flow gas streams that converge beyond the intersection of the wire free-end with the plasma-arc to limit turbulence of the plasma-arc, avoid direct impingement with the wire and assist the projection of the particles to the target surface; and impinging a low velocity gas flow along the axis of the advancing wire to counteract any destabilizing fluid dynamic forces attempting to move melted particles back along the wire away from the wire free end.

High deposition rate thermal spray using plasma transferred wire arc

A plasma transferred wire arc thermal spray apparatus and method producing an extended-arc and supersonic plasma jet stream for applying a dense metallic coating on a substrate, such as a concave internal surface of a bore. The apparatus includes a plasma generating torch assembling having a cathode and an anode nozzle surrounding the cathode and a wire feeder which continuously feeds the tip of a wire feedstock opposite a constricted nozzle orifice and wherein the wire feedstock is maintained at the same positive electrical potential as the nozzle. Plasma gas is directed into the nozzle, preferably generating a vortex flow around the cathode and exiting the restricted nozzle orifice. The improved apparatus includes a pilot power supply and a high voltage or high frequency power supply which initiates the electric arc and the constricted plasma arc and a separate main power supply which extends the constricted plasma arc to the wire tip. In the disclosed bore coating apparatus and method, the plasma torch assembly is rotated about the longitudinal axis of the wire feedstock while maintaining the electrical connection between the wire feedstock and the nozzle. The apparatus further includes an annular conical port surrounding the restricted nozzle orifice connected to a second gas source which generates an annular conical gas stream surrounding the wire tip having a point of intersection spaced downstream of the wire tip and the second gas is further directed to the wire feed guide to cool the assembly.

Plasma transferred wire arc thermal spray apparatus and method

A method of thermal spray coating a surface with a metal coating material includes the provision of a nozzle about a thermal spray coating apparatus, such as a two wire electric-arc apparatus. The nozzle includes a plurality of ports facing generally radially inwardly towards a coating material particle stream, such as an atomized molten metal stream of a two-wire arc thermal spray apparatus. The ports sequentially receive a deflecting gas flow, such that the direction moves circumferentially about the axis of the particle stream. The deflecting gas entrains the coating material and carries it radially to the surface of the part to be coated or the nozzle assembly. By utilizing a plurality of valve ports, one simplifies the assembly over prior art systems which have rotated the part to be coated. In one embodiment of this invention, a valve disk selectively communicates a compressed gas to the ports sequentially. In a second embodiment, each of the ports are associated with individual electrically operated valves which are sequentially opened to achieve the changing direction of the deflecting gas flow. A method and apparatus for simultaneously coating a plurality of bores main body, such as an engine block, is also disclosed. The apparatus includes a plurality of deflecting nozzles which are simultaneously inserted in each of the bore. The preferred method includes initiating an axial particulate coating stream, prior to inserting the deflecting nozzles in the bores, then inserting the nozzles in the bores and deflecting stream radially, to coat all of the bores simultaneously.

Method for thermal spray coating interior surfaces using deflecting gas

Apparatus and method for thermal spray coating interior surfaces

A high velocity arc spray apparatus includes a transferred-arc-plasma torch assembly which forms a transferred-arc column. A metal feedstock is fed into the transferred-arc column at an angle such that no portion of the metal feedstock is closer to the transferred-arc-plasma torch assembly than the leading edge of the metal feedstock in the feeding direction. A power source is coupled to both the metal feedstock and transferred-arc-plasma torch assembly for creating an electrical potential difference between the metal feedstock and the transferred torch assembly.

Growing community of inventors

East Norwich, NY, United States of America

Keith Alan Kowalsky