# US 11,306,384 B2 · Strengthening mechanism for thermally sprayed deposits > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,306,384 B2 - Document ID: US11306384B2 - Status: Granted - Kind: B2 - Application number: 16/010,294 - Filed: 2018-06-15 - Published: 2019-01-10 - Granted: 2022-04-19 - Earliest claimed: 2017-07-10 - Assignees: ResOps, LLC - Applicants: ResOps, LLC - Inventors: Joe L. Scott; Tien Thanh Le - Web page: https://patentgrep.com/patent/US11306384B2 ## CPC - C23C 4/06: Metallic material - B05C 3/04: with special provision for agitating the work or the liquid or other fluent material - C23C 4/123: Spraying molten metal - C23C 4/129: Flame spraying - C23C 4/131: Wire arc spraying - C23C 4/134: Plasma spraying - C23C 4/16: Wires; Tubes - C23C 4/18: After-treatment - C23C 28/021: {including at least one metal alloy layer} - E21B 17/02: Couplings; joints {(expandable couplings or joints E21B43/106)} - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08) - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS ## Abstract The present disclosure provides a method, system, and apparatus that adds one or more reinforcing structures to a thermally sprayed layer of metallic material onto a substrate to reinforce and/or further support the formed substrate coating. The reinforcing structure may be a metallic or non-metallic wire, filament, whisker, mesh, or similar structure and may be coupled to the substrate before or during the thermal spray process, thereby embedding the reinforcing structure(s) into the resulting thermal spray matrix. The type, material, size, shape, and application technique of the reinforcing structure is variable based upon the desired characteristics of the ultimate coating. The durable coating may be formed by a plurality of separate and/or distinct layers. The resultant coating (e.g., the reinforcing structure(s) with the one or more thermal spray layers) provides numerous benefits, including increased strength and resistance to spalling, breaking, cracking, deforming, crack formation, and corrosion. ## Claims ### Claim 1 A method for forming a coating on a substrate, comprising: providing a substrate having an external surface; thermally spraying a layer of metallic material on the external surface; embedding one or more reinforcing structures into the thermal spray layer, wherein the one or more reinforcing structures comprises mesh; and coupling the one or more reinforcing structures to the external surface during the thermally spraying step. ### Claim 2 (depends on 1) The method of claim 1, further comprising coupling the one or more reinforcing structures to the external surface prior to the thermally spraying step. ### Claim 3 (depends on 1) The method of claim 1, further comprising wrapping the one or more reinforcing structures around at least a portion of the substrate prior to the thermally spraying step. ### Claim 4 (depends on 1) The method of claim 1, further comprising bonding the thermal spray layer with the one or more reinforcing structures. ### Claim 5 (depends on 1) The method of claim 1, further comprising depositing the metallic material onto the substrate such that the material solidifies and forms into a layer of material on the substrate and around the one or more reinforcing structures. ### Claim 6 (depends on 1) The method of claim 1, further comprising forming a coating on the external surface that comprises the metallic material and the one or more reinforcing structures. ### Claim 7 (depends on 1) The method of claim 1, wherein the one or more reinforcing structures comprises a different material than the thermally sprayed material. ### Claim 8 (depends on 1) The method of claim 1, wherein the thermal spray technique comprises twin wire arc spray. ### Claim 9 (depends on 1) The method of claim 1, further comprising: thermally spraying a second layer of metallic material onto the first layer of metallic material; and embedding one or more reinforcing structures into the second layer of thermal spray. ### Claim 10 A method for applying a coating to a substrate, comprising providing a substrate having an external surface; coupling one or more reinforcing structures to the external surface, wherein the one or more reinforcing structures comprises mesh; thermally spraying a layer of metallic material onto the one or more reinforcing structures; and embedding the one or more reinforcing structures into the thermal spray layer, wherein the coating comprises a corrosion resistant layer. ### Claim 11 (depends on 10) The method of claim 10, wherein the one or more reinforcing structures comprises metallic or non-metallic material, wherein the coupling step comprises attaching the mesh to the external surface at the same time or prior to the thermally spraying step. ### Claim 12 (depends on 10) The method of claim 10, wherein the coupling step comprises attaching the one or more reinforcing structures to the external surface of the substrate using micro-welding. ### Claim 13 (depends on 10) The method of claim 10, further comprising depositing the metallic material onto the substrate such that the material solidifies and forms into a layer of material on the substrate and around the one or more reinforcing structures. ### Claim 14 (depends on 1) The method of claim 1, wherein the one or more reinforcing structures is non-metallic. ### Claim 15 (depends on 1) The method of claim 1, wherein the one or more reinforcing structures is metallic. ### Claim 16 (depends on 10) The method of claim 10, wherein the coating comprises greater wear resistance than a coating without the one or more reinforcing structures. ### Claim 17 (depends on 1) The method of claim 1, wherein the one or more reinforcing structures comprises a first material, and the layer of thermally sprayed material comprises a second material. ### Claim 18 (depends on 10) The method of claim 10, wherein the coating comprises a plurality of different thermally sprayed layers, wherein the coating comprises a first layer with a first composition and a second layer with a second composition. ### Claim 19 (depends on 10) The method of claim 10, wherein the coating comprises a thickness of at least 0.10 inches on the substrate. ### Claim 20 (depends on 10) The method of claim 10, wherein the coating comprises a thickness of less than 0.10 inches on the substrate. ### Claim 21 (depends on 1) The method of claim 1, further comprising wrapping the one or more reinforcing structures around at least a portion of the substrate during the thermal spraying step. ### Claim 22 (depends on 1) The method of claim 1, further comprising rotating the substrate during the thermal spraying step. ### Claim 23 (depends on 1) The method of claim 1, further comprising coupling the one or more reinforcing structures to the external surface during the embedding step. ### Claim 24 (depends on 1) The method of claim 1, further comprising coupling the one or more reinforcing structures to the external surface by coupling the one or more reinforcing structures with the sprayed layer of metallic material. ### Claim 25 (depends on 1) The method of claim 1, wherein the spraying step comprises thermally spraying both the substrate and the one or more reinforcing structures. ### Claim 26 (depends on 1) The method of claim 1, wherein the spraying step comprises thermally spraying both the substrate and the one or more reinforcing structures at substantially the same time. ### Claim 27 (depends on 1) The method of claim 1, wherein the coupling step occurs while wrapping the one or more reinforcing structures around at least a portion of the substrate and while rotating the substrate. ### Claim 28 (depends on 10) The method of claim 10, wherein the spraying step comprises thermally spraying both the substrate and the one or more reinforcing structures after being coupled to the substrate. ### Claim 29 (depends on 10) The method of claim 10, further comprising thermally spraying a layer of metallic material onto the exterior surface of the substrate. ### Claim 30 A method for forming a coating on a substrate, comprising: providing a substrate having an external surface; wrapping one or more reinforcing structures around at least a portion of the substrate, wherein the one or more reinforcing structures comprises mesh; and thermally spraying a layer of metallic material on the external surface; and coupling the one or more reinforcing structures to the substrate via the sprayed layer of metallic material. ### Claim 31 (depends on 30) The method of claim 30, wherein the spraying step comprises spraying the layer of metallic material on the one or more reinforcing structures. ### Claim 32 (depends on 30) The method of claim 30, further comprising embedding the one or more reinforcing structures into the thermal spray layer. ### Claim 33 A method for forming a coating on a substrate, comprising: providing a substrate having an external surface; thermally spraying a layer of metallic material on the external surface; embedding one or more reinforcing structures into the thermal spray layer, wherein the one or more reinforcing structures comprises mesh; and rotating the substrate during the thermal spraying step.