Ford Global Technolgoies, LLC

Ford Motor Company Limited

Larry Gerald Gargol

John Edward Chancey

Lawrence Edward Ellis

Srikanth Chinthagunta Reddy

David James Cook

Daniel R Marantz

Keith Alan Kowalsky

Joseph Swithan Vanselous

The present invention provides a plasma transferred wire arc torch assembly that includes a monolithic block assembly that combines into a single component several features that have previously been separate components. The monolithic block of the present invention combines the functions of a wire guide, an air baffle, and a nozzle. Integration of this components allows for a reduction in size of the plasma transferred wire arc torch assembly thereby making it possible to coat smaller diameter bores with metal.

Small bore PTWA thermal spraygun

The present invention provides a nonflammable ternary gas mixture to be used in a plasma machining operation. The ternary gas mixture of the present invention comprises from about 4% to about 6.2% hydrogen, 30% to 50% argon, and the balance nitrogen. In another embodiment of the present invention, a method of generating a high pressure plasma is provided. The method of this embodiment comprises introducing the ternary gas mixture of the present invention into a plasma torch apparatus, initiating a plasma in the plasma torch apparatus, and sustaining the plasma with a high voltage between a cathode and an anode.

Nonflammable ternary gas mix for high pressure plasmas

An aluminum pressure plate and flywheel, for a clutch in a vehicle drivetrain, have wear resistant surfaces applied at the clutch disc interface. The wear resistant surfaces are applied to the pressure plate and flywheel using a plasma transferred wire arc thermal spray process.

Clutch pressure plate and flywheel with friction wear surfaces

A cathode assembly for an electric arc spray apparatus. The cathode assembly utilizes a positive cathode retention design which provides for improved heat management characteristics, quick and easy cathode replacement and increased cathode life. The cathode assembly includes a cathode holder , a cathode including a first portion which resides within the cathode holder , a tip portion which extends from the cathode holder, and a shoulder portion which is formed on the outer surface of the cathode. The cathode assembly further includes a retention member or nut which removably attaches to the cathode holder and which engages the shoulder portion , effective to positively retain the cathode within the holder . The retention member also includes an aperture through which the cathode tip extends. The cathode retention member allows for a longer and larger cathode to be utilized and provides an increased amount of heat dissipating surfaces relative to prior designs, thereby increasing the life and improving the performance of the cathode.

Cathode assembly for an electric arc spray apparatus

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.

Growing community of inventors

Ann Arbor, MI, United States of America

Larry Gerald Gargol