Abstract:
A high temperature thermal sprayable material, such as a metal or metal oxide, is adhered to the surface of a thermal sprayable plastic particle to form a cladding layer thereon. The high temperature material cladding layer provides a thermal barrier that allows use of the plastic in a high temperature thermal spray process to create a duplex coating containing plastic.
Abstract:
Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, die or forming tool comprising the steps of: a) providing a body support member having a controlled and designed porosity which permits the enhancement of the heat transfer ability of said mold, die or forming tool; b) configuring a surface of the support member to a desired cavity; and c) spraying particles to the configured cavity in the support member, thereby producing a mold, die or forming tool. Preferably, the materials of construction are metallic and are applied by thermal plasma spraying. The particles may also be ceramics, metal matrix composites, ceramic matrix composites, thermoplastic resins, thermoset resins, and composites based thereupon. The controlled porosity of the body of the mold, die and/or forming tool is as important as the use of thermal spray to subsequently form the cavity.
Abstract:
A method of making anti-friction coated surfaces subject to sliding wear, comprising: (a) forming grains of agglomerated solid lubricant particles and air-hardenable, fusable ingredients such as steel particles, the particles being agglomerated by a low melting medium such as wax; (b) providing a light metal-based component surface; (c) thermally spraying such grains onto said surface in a thickness range of 100-250 microns to form a coating substantially devoid of the low melting medium (the temperature of said thermal spraying liquifying and eliminating the wax by ash-free combustion); (d) removing at least a portion of the fusable particles by honing to expose edges of such particles; and (e) subjecting the exposed particles to air hardening (i.e., by available interfacing friction).
Abstract:
A process for depositing a diamond coating on a substrate at temperatures less than about 550.degree. C. A powder mixture of glassy carbon and diamond particles is passed through a high velocity oxy-flame apparatus whereupon the powders are heated prior to impingement at high velocity against the substrate. The powder mixture contains between 5 and 50 powder volume percent of the diamond particles, and preferably between 5 and 15 powder volume percent. The particles have a size from about 5 to about 100 micrometers, with the diamond particles being about 5 to about 30 micrometers. The flame of the apparatus provides a velocity of about 350 to about 1000 meters per second, with the result that upon impingement upon the substrate, the glassy carbon is phase transformed to diamond as coaxed by the diamond content of the powder mixture.
Abstract:
The invention provides a composition of matter comprising silicon, silicon carbide and boron carbide as a coating for protecting carbon substrates from degradation at elevated temperatures. The invention also provides a method for forming a protective coating on carbon substrates by utilizing the aforesaid composition of matter.
Abstract:
The method of making a composite article of different metal portions by spraying molten metal on the surface of a solid metal member that has been cleaned and preheated in a controlled atmosphere at low pressure. The molten metal is sprayed on the surface of the solid metal member, preferably by plasma jet spraying. It is rapidly solidified to be adherent to the surface of the solid metal member to form a composite preform. The composite preform is cooled at a rate sufficiently low to reduce residual stresses and then hot pressed to eliminate voids in the sprayed metal portion and metallurgically bonded to the surface of the solid member.
Abstract:
Stainless steel foil 31 is wound spirally on the circumference of a pipe body 30 from one end to another end of the pipe body 30 to overlap itself and the periphery of the pipe body 30 is covered with the overlapped layer to give a heat insulation pipe body. The stainless steel foil 31 is wound on the circumference of the pipe body 30 from one end thereof, while ceramic particles 32 are flame sprayed to the wound part of the stainless steel foil 31 to form a ceramic particle dotted layer 33. Then on the periphery of the stainless steel foil 31 with the ceramic particle dotted layer 33 formed, a part of the stainless steel foil subsequent to one end of said stainless steel foil is wound shiftedly toward an axis direction and at the same time the newly wound stainless steel foil part is flame sprayed with ceramic particles 32 to form a ceramic particle dotted layer 33 and these steps are repeated.
Abstract:
A process for producing a magnetite-coated electrode which comprises kneading an iron oxide powder, water and an organic binder under pressure sufficient to prepare a molded article, baking the molded article in a gas atmosphere mainly composed of a member selected from the group consisting of carbon dioxide and steam to prepare a magnetite sinter having an Fe to 0 ratio of 3:3.7 to 4.0, pulverizing the sinter to prepare a powder, and subjecting a metallic substrate to plasma spray coating, plasma jet spray coating, explosive spray coating and water plasma spray coating by making use of the powder as the spray coating source in a neutral gas atmosphere to form a magnetite coating on the surface of the metallic substrate.
Abstract:
Methods and apparatus are provided for applying a colorant material to the surface of a plastic insulation material which has been applied to an elongated material such as a metallic conductor (22) or an optical fiber which is being moved at any of a wide range of speeds along a path of travel. The colorant material is applied by nozzles which are staggered along the path of travel and which direct the colorant into engagement with the plastic insulation material at different radial directions. A first plurality of nozzles (46--46) each cause the colorant to be in a spray pattern (45) which is in the area of a plane. Advantageously, those nozzles cooperate to stabilize the conductor and prevent undulations thereof as the conductor is moved along its path of travel. A second plurality of nozzles (50--50) cause the colorant to be in a solid conical pattern (53). The first and the second pluralities of nozzles are effective to cause substantially all the surface area of the plastic insulation on successive increments of length of the conductor to be covered with the colorant material.
Abstract:
A method and means of applying a continuous antifouling coating of copper or copper alloys on hulls of ships or boats by the application of sealing and adhesive layers, followed by a coating of thermally sprayed copper particles to form the antifouling layer.