High velocity thermal spray apparatus
OwnerVladimir Belashchenko, Andrei Voronetskiinventors
Life of this patent
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Abstract
A thermal spray apparatus is provided for thermal spraying a coating onto a substrate. The apparatus include a heating module for providing a stream of heated gas. The heating module is coupled to a forming module for controlling pressure and velocity characteristics of the stream of heated gas generated by the heating module. The thermal spray apparatus further includes a barrel capable of directing the stream of heated gas from the forming module. A powder injection module may be provided for introducing powder material into the stream of heated gas.
Claims40
A thermal spray apparatus comprising:
- a heating module for providing a stream of heated gas;
- a forming module coupled to said stream of heated gas, said forming module comprising a first zone having an entrance coupled to said stream of heated gas and an exit coupled to a throat having a constant cross-sectional area, and a second zone having an entrance coupled to said throat and an exit;
- a barrel coupled to said exit of said forming module;
- a powder injection module comprising at least one powder injector for introducing powder material into said stream of gas;
- and
- a shockwave generator;
- where the ratio between the cross-sectional area of the exit of the second zone and the cross-sectional area of the throat=Kn2 (1.7+0.1 Pcc/Pa)2, wherein Pcc is absolute pressure in the heating module, Pa is atmospheric pressure, and Kn is in the range of between about 0.5 to about 0.8.
A thermal spray apparatus comprising:
- a forming module comprising at least two sub-forming blocks, each sub-forming block coupled to a gas stream and each sub-forming block comprising a converging zone having an inlet diameter that is greater exit diameter, a throat having a constant cross-sectional area, and an expansion zone having an exit diameter that is greater than an inlet diameter;
- and
- a barrel coupled to an exit of each sub-forming block.
A thermal spray apparatus comprising:
- a forming module coupled to a stream of gas, said forming module comprising a converging zone having an entrance and an exit, said entrance having a greater cross-sectional area than said exit;
- a throat having a constant cross-sectional area, said throat coupled to said exit of said converging zone;
- and an expansion zone having an entrance and an exit, said entrance having a cross-sectional area smaller than a cross-sectional area of said exit, said entrance of said expansion zone coupled to said throat;
- and
- a powder injector introducing a powder material into said stream of gas, said powder injector oriented parallel to an axis of said forming module and disposed at least partially within said forming module, said powder injector having a cross-sectional profile that at least partially defines said cross-sectional areas of at least one of said converging zone, said throat, or said expansion zone.
Dependencies are inferred from the claim text.