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US 2026/0159933 A1Published application
Structurally enhanced roughened features for improved thermal spray device and method of use for producing uniform coating properties
AssigneePraxair S.T. Technology, Inc.
InventorDavid A. Somerville
Life of this patent
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Abstract
A novel and improved thermal spray component having structurally enhanced roughened features on a wetted surface is provided. The structurally enhanced roughened features on the wetted surface enable a reduction in the accumulation of scale deposits and also improves coating property performance during operation of the thermal spray torch.
Claims22
An improved thermal spray apparatus for use in production of a thermal spray coating, said improved thermal spray apparatus comprising:
- a high velocity oxygen fuel (HVOF) torch for spraying, wherein said torch includes a combustion chamber having an interior volume defined by interior surfaces, said combustion chamber configured to receive oxygen and a fuel and allow combustion reaction products to be produced that generate a heated flow therefrom and which are in contact with said interior surfaces, said combustion chamber comprising a first outer surface in contact with cooling media;
- a barrel operably connected downstream to said combustion chamber, said barrel having an interior volume defined by interior surfaces configured to be in contact with the heated flow of said combustion reaction products, said barrel comprising a second outer surface in contact with the cooling media;
- at least one of said first outer surface of said combustion chamber and said second outer surface of said barrel characterized by structurally enhanced roughened features, wherein said structurally enhanced roughened features are configured to reduce an accumulation of scale deposits on said first and/or second outer surface when said first and/or second outer surface is exposed to cooling media during the operation of the HVOF torch.
An improved thermal spray apparatus for use in a production of thermal spray coating, said improved thermal spray apparatus comprising:
- a plasma torch for spraying wherein said torch includes a cathode device, and an anode, said anode having an exterior surface and an interior portion, wherein the interior portion of the anode is operably connected to the cathode device, and further wherein the exterior surface of the anode is in fluid communication with a cooling media;
- said exterior surface of the anode characterized by structurally enhanced roughened features, wherein said structurally enhanced roughened features are configured to reduce an accumulation of scale deposits on said external surface of the anode when exposed to cooling media during the operation of the plasma torch.
An improved thermal spray component for use in a thermal spray apparatus to create a thermal spray coating, said improved thermal spray component comprising:
- a body having a substantially tubular geometry, said substantially tubular geometry having a first end and a second end, wherein a central longitudinal axis traverses the body from the first end to the second end, the body having a first surface that is adapted to be in contact with a plasma arc or combustion reaction products when said thermal spray component is operably connected within the thermal spray apparatus, the body further having a second surface that extends from the first end to the second end, the second surface configured to be in contact with cooling media during operation of the thermal spray apparatus;
- and
- a structurally enhanced roughened feature along at least a portion of the second surface, said structurally enhanced roughed feature being oriented substantially parallel to the central longitudinal axis, wherein said structurally enhanced roughened features are configured to reduce an accumulation of scale deposits on said second surface when said second surface is exposed to the cooling media during the operation of the thermal spray apparatus.
An improved thermal spray component for use in a thermal spray apparatus to create a thermal spray coating, said improved thermal spray component comprising:
- a body having a substantially tubular geometry, said substantially tubular geometry having a first end and a second end, wherein a central longitudinal axis traverses the body from the first end to the second end, the body having a first surface that is adapted to be in contact with a plasma arc or combustion reaction products when said thermal spray component is operably connected within the thermal spray apparatus;
- the body further having a second wetted surface that extends from the first end to the second end, wherein at least a portion of the second wetted surface comprises a structurally enhanced roughened feature that is configured to be in contact with cooling media during operation of the thermal spray apparatus.
A method of creating consistent coating properties during operation of an improved thermal spray apparatus, comprising the steps of:
- creating a high temperature energy source with the improved thermal spray apparatus comprising at least one thermal spray component having a wetted surface, said wetted surface having a structurally enhanced roughened feature therealong;
- introducing powder or wire feedstock into an inlet of the improved thermal spray apparatus;
- heating the powder or the wire feedstock to produce substantially molten particles;
- introducing cooling media into the improved thermal spray apparatus so as to contact the wetted surface having the structurally enhanced roughened feature therealong;
- directing the substantially molten particles onto a substrate to produce a coating, wherein said coating includes at least one coating property that exhibits variation during the operation of the improved thermal spray apparatus that is less than that produced with a thermal spray apparatus that does not contain the at least one thermal spray component, said at least one coating property selected from the group consisting of porosity, deposition thickness, microhardness and residual stress.
2 more elements
Dependencies are inferred from the claim text.