Flameless thermal spray system using flame heat source

摘要

An apparatus and method for forming a fusible coating or structure comprising a combustor that is operative to combust a fuel and contain the resulting flame to produce combustion products; means for cooling the combustion products to produce a hot carrier gas stream; and means for introducing fusible material into the hot carrier gas stream.

主权项

1. A thermal spray gun, comprising:
an exterior surface; an inner chamber located within the exterior surface having a forward end and an aft end; a flame source located within the inner chamber; a first fluid passageway located within the inner chamber for carrying a combustible mixture to the flame source, wherein the flame source produces a combustion gas when a flame is present; a second fluid passageway located within the inner chamber for carrying excess gas to a flame produced by the flame source; a third fluid passageway located between the exterior surface of the thermal spray gun and a wall of the inner chamber of the thermal spray gun, wherein the third fluid passageway is configured to carry a cooling gas to cool the exterior surface and to carry the cooling gas to the inner chamber to mix with the combustion gas; a nozzle for introducing a gas-particle mixture into the combustion gas mixed with the cooling gas; and a deflector positioned adjacent a distal end of the second fluid passageway and extending radially outward therefrom; wherein the deflector is configured to direct the excess gas at least partially across the flame source; wherein an outlet of the third fluid passageway is located downstream from the flame source and between the flame source and an outlet of the nozzle.