Plasma-Kinetic Spray Apparatus and Method

摘要

A coating system that applies a coating of particles to a surface of an article. The coating system comprises a hybrid plasma torch which may include a cathode, a first plasma gas chamber, a first mixing chamber, a plasma generator for generating an arc column of plasma, a second mixing chamber for mixing a main gas, an at least partially ionized first plasma gas and a second gas that was mixed in the first mixing chamber, wherein the second mixing chamber is dimensioned to receive a plurality of powder particles suspended in a carrier gas, and an accelerator assembly for accelerating the mixture of the main gas, the at least partially ionized first plasma gas, the second plasma gas and the powder particles into a high-velocity stream and for directing the high-velocity stream against the surface of the article. A method of applying the coating of particles is also provided.

主权项

1. A coating system that applies a coating of particles to a surface of an article, the coating being formed of cohesive layers of particles in the solid state, the coating system comprising a plasma-kinetic torch assembly comprising:
a cathode; a first plasma gas chamber for receiving a first plasma gas that becomes at least partially ionized therein, wherein the first plasma gas chamber comprises a restricted orifice out of which the at least partially ionized first plasma gas exits; a first mixing chamber for receiving a second plasma gas and the at least partially ionized first plasma gas, wherein the second plasma gas and the at least partially ionized first plasma gas are mixable in the first mixing chamber, and wherein the first mixing chamber acts as a first anode, a plasma generator for generating an arc column of plasma between at least the cathode and the first anode; a second mixing chamber for receiving a main gas that is mixable with the second plasma gas and the at least partially ionized first plasma gas that was mixed in the first mixing chamber, wherein the second mixing chamber is dimensioned to receive a plurality of powder particles suspended in a carrier gas; an accelerator assembly for accelerating the mixture of the main gas, the at least partially ionized first plasma gas, the second plasma gas and the powder particles into a high-velocity stream and for directing the high-velocity stream against the surface of the article; whereby the powder particles are caused to adhere to the article and form the coating of particles.