Wire Arc Spray Swivel Head

A method of thermal spray coating a workpiece comprising steps, not necessarily conducted in series, as follows:

• providing the workpiece to be thermal spray coated;
• providing a device for thermal spray coating, which includes a wire arc spray swivel head having the following:
• a first member including a torch body, with a first central axis passing through the torch body;
• and
• pivotally attached to the first member, a second member including electric arc-making contact points and a carrier gas outlet in a spray tip having a distal end thereto, with a second central axis passing through the second member;
• wherein the second member is configured to pivot with feed wire in a pivoting motion with respect to the torch body when the wire arc spray swivel head is operated for spraying the thermal spray coating, with the pivoting motion being such that the second member is configured to be adjusted pivotally with respect to the torch body while the second member remains attached to the torch body to flex within a curvilinear arc from a first position in relation to the torch body to a second position in relation to the torch body such that in the first position a first angle is formed between said first central axis and said second central axis, and in the second position a second angle is formed between said first central axis and said second central axis that is different from the first angle, wherein the second member flexes with respect to the first member, by which the second member and said second central axis is moved in or parallel to a predetermined, fixed plane in which said first central axis of the torch body resides;
• wherein, during operation, the feed wire is provided as solid feed wire pulled into the first member and from there fed into the second member to be melted about the electric arc-making contact points and sprayed out the spray tip with carrier gas, which passes through the second member, past the electric arc-making contact points, and out the carrier gas outlet for thermal spraying therefrom;
• wherein the second member flexes with respect to the first member through a substantial radial arc;
• and wherein, when operating for the thermal spray coating, the device operates to thermal spray coat the workpiece;
• providing wire feed stock in a solid state to the head of the device;
• swiveling the head in a pivoting motion to orient it in position for spraying the workpiece;
• providing electric power to the solid wire feed stock such that the solid wire feed stock is changed into a state suitable for thermal spraying;
• providing a carrier gas under pressure to the device;
• passing the carrier gas by the feed stock changed into a suitable state for thermal spraying to form a molten spray for thermal coating the workpiece;
• and
• carrying the molten spray by the carrier gas to the workpiece such that thermal spray coating is carried out on the workpiece.