Claims
- 1. A process for forming an adherent rough coating on a receiving surface of an article to provide a slip resistant surface for persons walking or working thereon comprising the steps of:
- providing a hollow wire filled with fill materials including iron and alloying elements with iron,
- said hollow wire being constructed from iron,
- thermally acting on said hollow wire and said materials to heat said iron to its alloying temperature to provide molten metal droplets forming an iron alloy including at least some of said fill materials,
- directing said molten metal droplets as a spray against said receiving surface to form an adherent rough coating defining a slip resistant surface for persons walking or working thereon,
- said slip resistant surface of said iron alloy having a hardness of between around 40 Rc to around 65 Rc.
- 2. The process of claim 1 with said fill materials and said hollow wire forming said molten metal droplets comprising mainly iron and with said slip resistant surface having a hardness of between around 50 Rc to around 65 Rc.
- 3. The process of claim 1 with said molten metal droplets comprising, by weight, mainly iron and between around 0.25% to around 0.70% carbon.
- 4. The process of claim 1 with the combined materials forming said molten metal droplets comprising, by weight, mainly iron and between around 0.30% to around 0.60% carbon.
- 5. The process of claim 1 with the combined materials forming said molten metal droplets comprising, by weight, between around 0.25% to around 0.70% carbon, and between around 1% to around 3% aluminum and the remainder being substantially iron.
- 6. The process of claim 1 with the combined materials forming said molten metal droplets comprising, by weight, between around 0.30% to around 0.60% carbon, and between 1% to around 3% aluminum and the remainder being substantially iron.
- 7. The process of claim 1 with said fill materials further including grit particles.
- 8. The process of claim 1 with said fill materials including generally between around 25% to around 50% by volume of grit particles and the remainder of said fill materials and said hollow wire providing said metal droplets.
- 9. The process of claim 1 with said fill materials including between around 25% to around 50% by volume of grit particles and the remainder of materials including said fill materials and said hollow wire including a metal from the group including aluminum and iron.
- 10. The process of claim 1 with said fill materials including between around 25% to around 50% by volume of grit particles and the rest of said fill materials and said hollow wire, comprising, by weight, between around 0.25% to around 0.70% carbon and the remainder being substantially iron.
- 11. The process of claim 1 with said fill materials including between around 25% to around 50% by volume of grit particles and the rest of said fill materials and said hollow wire comprising, by weight, between around 0.25% to around 0.70% carbon, between around 1% to around 3% aluminum and the remainder being substantially iron.
- 12. The process of claim 1 with said iron alloy in said slip resistant surface being generally martensitic in nature.
- 13. The process of claim 1 with said hollow wire being of a generally ductile material.
- 14. The process of claim 1 with said hollow wire being of a generally ductile material providing by weight between around 30% to around 70% of the iron of said hollow wire and said fill materials combined.
- 15. In a process for forming a product having an adherent rough coating on a receiving surface to provide a slip resistant surface for persons walking or working thereon, the product formed by such process including the steps of:
- providing a hollow wire filled with fill materials including iron and alloying elements with iron,
- thermally acting on said hollow wire and said fill materials to heat said iron to its alloying temperature and to provide molten metal droplets forming an iron alloy including said alloying elements,
- directing said molten metal droplets as a spray against said receiving surface to form an adherent rough coating defining a slip resistant surface for persons walking or working thereon,
- said slip resistant surface being formed with said iron alloy having a Rockwell hardness of between around 40 Rc to around 65 Rc.
- 16. The process for forming the product of claim 15 with the combined materials forming said molten metal droplets comprising, by weight, mainly iron and between around 0.25% to around 0.70% carbon.
- 17. The process for forming the product of claim 15 with the combined materials forming said molten metal droplets comprising by weight mainly iron and between around 0.30% to around 0.60% carbon.
- 18. The process for forming the product of claim 15 with the combined materials forming said molten metal droplets comprising, by weight, between around 0.25% to around 0.70% carbon, and between around 1% to around 3% aluminum and the remainder being substantially iron.
- 19. The process for forming the product of claim 15 with the combined materials forming said molten metal droplets comprising, by weight, between around 0.30% to around 0.60% carbon, between 1% to around 3% aluminum and the remainder being substantially iron.
- 20. The process for forming the product of claim 15 with said fill materials further including grit particles.
- 21. The process for forming the product of claim 15 with said materials including between around 25% to around 50% by volume of grit particles and with the rest of said fill materials and said hollow wire providing said metal droplets.
- 22. The process for forming the product of claim 15 with said materials including between around 25% to around 50% by volume of grit particles and with the rest of said fill materials including a metal selected from the group consisting of aluminum and iron.
- 23. The process for forming the product of claim 15 with said fill materials including between around 25% to around 50% by volume of grit particles and the rest of said fill materials including said wire, comprising by weight, between around 0.25% to around 0.70% carbon and the remainder being substantially iron.
- 24. The process for forming the product of claim 15 with said fill materials including between around 25% to around 50% by volume of grit particles and the rest of said fill materials with said wire comprising, by weight, between around 0.25% to around 0.70% carbon, between around 1% to around 3% aluminum and the remainder being substantially iron.
- 25. The process for forming the product of claim 15 with said hollow wire being of a generally ductile material.
- 26. The process for forming the product of claim 15 with said hollow wire being of a generally ductile material providing by weight between around 30% to around 70% of the iron of said hollow wire and said fill materials combined.
- 27. The process for forming the product of claim 15 with said iron alloy in said slip resistant surface having a Rockwell hardness of between around 50 Rc to around 60 Rc.
- 28. In a process for forming a product having an adherent rough coating on a receiving surface to provide a slip resistant surface for persons walking or working thereon, the product formed by such process including the steps of:
- providing a hollow wire filled with fill materials including iron and alloying elements with iron,
- thermally acting on said hollow wire and said fill materials to heat said iron to its alloying temperature and to provide molten metal droplets forming an iron alloy including said alloying elements,
- directing said molten metal droplets as a spray against said receiving surface to form an adherent rough coating defining a slip resistant surface for persons walking or working thereon,
- said slip resistant surface being jagged and generally defined by randomly distributed sharp ridges and pointed peaks of varying depths,
- said slip resistant surface being formed with said iron alloy having a Rockwell hardness of between around 40 Rc to around 65 Rc.
- 29. The process for forming the product of claim 27 with said iron alloy in said slip resistant surface being generally martensitic in nature, said iron alloy in said slip resistant surface having a Rockwell hardness of between around 40 Rc to at least around 65 Rc.
- 30. The process for forming the product of claim 28 with said iron alloy in said slip resistant surface having a Rockwell hardness of between around 50 Rc to at least around 65 Rc.
- 31. A process for forming an adherent, rough coating on a receiving surface on an article to provide a slip resistant surface for persons walking or working thereon comprising the steps of:
- providing a hollow wire filled with fill materials including iron and alloying elements with iron,
- thermally acting on said hollow wire and said fill materials to heat said iron to its alloying temperature to provide molten metal droplets forming an iron alloy,
- directing said molten metal droplets as a spray against said receiving surface to form an adherent rough coating defining a slip resistant surface for persons walking or working thereon,
- said molten metal droplets being directed by spray apparatus, and
- selectively controlling said spray apparatus relative to said receiving surface to spray said metal droplets to form a preselected coating pattern on said receiving surface of coated and generally uncoated portions,
- said coated portions being formed with said iron alloy having a Rockwell hardness of between around 40 Rc to around 65 Rc.
- 32. The process of claim 31 with said coated portions covering no less than around 30% and no greater than around 80% of the area of said receiving surface.
- 33. The process of claim 31 with said coated portions being formed to a depth of at least around 0.010' whereby said generally uncoated portions of said receiving surface can collect fluids.
- 34. In a process for forming a product having an adherent, rough coating on a receiving surface to provide a slip resistant surface for persons walking or working thereon the process comprising the steps of:
- providing a hollow wire filled with fill materials including iron and alloying elements with iron,
- thermally acting on said hollow wire and said fill materials to heat said iron to its alloying temperature to provide molten metal droplets,
- directing said molten metal forming an iron alloy droplets as a spray against said receiving surface to form an adherent rough coating defining a slip resistant surface for persons walking or working thereon,
- said molten metal droplets being directed by spray apparatus, and
- selectively controlling said spray apparatus relative to said receiving surface to spray said metal droplets to form a preselected coating pattern on said receiving surface of coated and generally uncoated portions, said slip resistant surface being jagged and generally defined by randomly distributed sharp ridges and pointed peaks of varying depths,
- said slip resistant surface being formed of an iron alloy having a Rockwell hardness of from around 40 Rc to around 65 Rc.
- 35. The process for forming the product of claim 34 with said coated portions covering no less than around 30% and no greater than around 80% of the area of said receiving surface.
- 36. The process for forming the product of claim 34 with said coated portions being formed to a random depth with the maximum depth being no less than around 0.010" whereby said generally uncoated portions of said receiving surface can collect fluids.
Parent Case Info
This is a continuation of U.S. Pat. application Ser. No. 07/110,950, filed Oct. 20, 1987 now abandoned.
US Referenced Citations (9)
Continuations (1)
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Number |
Date |
Country |
Parent |
110950 |
Oct 1987 |
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