Wire electrode with core of multiplex composite powder, its method of manufacture and use

A cored wire electrode for a thermal spray or welding apparatus, comprising:

• a sheath;
• and
• a multiplex powder composite that is contained within the sheath before the sheath is exposed to an electrical current in a thermal spray or welding environment, the composite comprising:
• a powder with a group of particles consisting of
• specie (A), comprising micron sized particles having an average diameter of about 1×10−6 meters and
• specie (B), consisting of sub-micron sized particles,
• specie (B) including specie (C), comprising nano-scale particles having an average diameter of about 1×10−9 meters, and specie (1), also comprising particles sized between specie (A) and specie (C),
• species (A) and (B) mechanically cooperating to promote smooth powder flow, which facilitates compaction of the cored wire,
• wherein the multiplex powder composite has the characteristics of relatively uniform density,
• wherein the particles of specie (C) move relatively easily in relation to those particles of specie (A) during compression of a sheath in which they are contained during mechanical reduction steps to which the sheath is subjected in manufacture of the cored wire electrode, thus reducing clumping or island-void problems that may adversely affect stiffness or malleability of the cored wire electrode.