System, apparatus, and method for deflected thermal spraying

BACKGROUND OF THE INVENTION

The invention relates generally to the spraying of a substance onto a surface. More specifically, the invention is a plasma transferred wire arc (“PTWA”) system, apparatus, and method for deflected thermal spraying (collectively, the “system”).

A. Plasma

There are four “states of matter” in physics. Matter can take the form of: (1) a solid; (2) a liquid; (3) a gas; or (4) a plasma. Plasma is an ionized gas consisting of positive ions and free electrons in equal proportions resulting in essentially no overall electric charge. Like a gas, plasma does not have a definitive shape or volume. It will expand to fill the space available to it. Unlike gases, plasmas are electrically conductive. Plasma conducts electricity, produces magnetic fields, and responds to electromagnetic forces. In plasma, positively charged nuclei travel in a space filled of freely moving disassociated electrons. These freely moving electrons allow matter in a plasma state to conduct electricity.

Although the term “plasma” is not commonly used outside the context of science and engineering, there are many common examples of plasma that people encounter in everyday life. Lightning, electric sparks, fluorescent lights, neon lights, and plasma televisions are all examples of plasma. Gas is typically converted into a state of plasma through heat (e.g. high temperatures) or electricity (e.g. a high voltage difference between two points).

B. Thermal Spraying

Thermal spraying is a process by which a material is sprayed onto a surface with the purpose of improving the surface that is being sprayed. There are many different types of thermal spraying, including, but not limited to: plasma spraying; detonation spraying; wire arc spraying; plasma transferred wire arc spraying; flame spraying; high velocity oxy-fuel coating spraying (“HVOF”); warm spraying; and cold spraying.

Two of these thermal spraying techniques involve the use of plasma, plasma spraying and plasma transferred wire arc spraying. Plasma spraying involves the introduction of feedstock, which can be in the form of a powder, a liquid, a ceramic feedstock that is dispersed in a liquid suspension, or a wire that is introduced into a plasma jet created by a plasma torch. Plasma transferred wire arc (“PTWA”) spraying is plasma spraying when the feedstock is electrically part of the circuit and is in the form of a wire.

C. PTWA—Plasma Transferred Wire Arc technology

PTWA can be used to enhance the surface properties of components. Treated components can be protected against extreme heat, abrasion, corrosion, erosion, abrasive wear, and other environmental and operational conditions that would otherwise limit the lifespan and effectiveness of the treated component. Overall durability is enhanced, while at the same time PTWA can also be used to achieve the following advantages with respect to treated components: (1) reductions in weight; (2) cost savings; (3) reduction in friction; (4) and a reduction of stress. In the context of vehicles such as automobiles, PTWA treatment of engine components such as cylinder bores can result in increased fuel economy and lower emissions. PTWA can also be useful in refurbishing old parts as well as in enhancing new parts.

The inputs of a PTWA system are electricity, gas, and consumable feedstock. The consumable feedstock is. the wire that is atomized by a plasma arc created between the cathode and the free end of the wire. The output of a PTWA system is a plasma arc between a cathode and an anode, where the anode is an open end of a consumable wire. The plasma spray is what enhances the surface properties of a component or surface being treated. Feedstock in a PTWA system is delivered to the plasma torch in the form of the wire. Electric current travels through the wire as the free end of the wire is moved to where the generated plasma exits the nozzle of the plasma torch. In many PTWA systems, the torch assembly revolves around a longitudinal axis of the wire feedstock while maintaining an electrical connection, a plasma arc, between the cathode of the plasma torch and the open end of the wire feedstock. In some embodiments, there is an offset between the longitudinal axis of the wire feedstock and the center of revolution (from the perspective of a cathode revolving around a center point) or the center of rotation (from the perspective of a cathode and surrounding empty space rotating around a center point). See U.S. Pat. No. 8,581,138 which discloses a thermal spray technology “wherein the method includes the steps of offsetting the central axis of a consumable wire with respect to an axial centerline of a constricting orifice.”

PTWA technology can provide highly desirable benefits in the treatment of components used in a wide variety of different industries, including but not limited to: aerospace; automotive; commercial vehicles; heavy industrial equipment; and rail.

D. Operating Parameters

The correct functioning of a PTWA system typically requires the tight coordination of three key parameters: (1) a straight and rapidly traveling feed wire between about 100-500 inches/minute; (2) stable current traveling through the rapidly traveling feed wire; and (3) a consistent gas flow/pressure sufficient for sustaining stable plasma temperatures typically between 6,000 and 20,000 degrees Celsius. If one or more of the parameters of a PTWA system fall outside the desired ranges, inconsistent melting of the feed wire can result. Such inconsistency can negate the desired advantages of PTWA spraying.

The correct functioning of a PTWA system requires the coordination of different variables under substantially tight constraints. Operations outside those constraints are not necessarily visible to the human eye unless the undesirable effects are severe. For example, a PTWA system functioning outside of desired parameters can result in “spitting” because the system will project large molten globules instead of finely atomized particles onto the surface being treated by the PTWA system. Even before visible “spitting” occurs, the operation of a PTWA system with even one parameter outside of an acceptable range can be highly undesirable.

E. Use of Secondary Gas

Prior art PTWA systems utilize secondary gas such as air to direct the particle stream in manner so that the particle stream impacts the targeted surface in the desired manner. In most instances, secondary gas is directed through the nozzle to a help shape the particle stream in a substantially symmetrical and collimated manner, with the sprayed particle stream being perpendicular to the wire. The centerline of the particle stream is typically in line with the horizontal plane (the plane that is perpendicular to the wire). The particle stream is typically directed in the same direction as the center vector.

The prior art presumes that the symmetrical direction of secondary gas to the particle stream is the optimal approach for quality coatings. The prior art affirmatively teaches away from the concept that the horizontal deflection of the particle stream is desirable. Such deflection significantly reduces collimation in the spray pattern and changes the geometry of the spray pattern. In the context of a cathode that rotates around the wire, it is counter-intuitive in the prior art to purpose deflect the particle stream against the direction of the cathode rotation or even in the same direction as the rotation of the cathode. Despite the teachings and assumptions of the prior art, horizontal deflection can be highly desirable.

The system can be further understood as described in the Summary of the Invention section set forth below.

SUMMARY OF THE INVENTION

The invention relates generally to the spraying of a substance onto a surface. More specifically, the invention is a plasma transferred wire arc (“PDA/A”) system, apparatus, and method for deflected thermal spraying (collectively, the “system”).

The system can be conceptualized and implemented as an improvement to a wide range of prior art spraying devices and plasma torches, but is particularly useful, novel, and non-obvious in the context of PTWA technology.

In many embodiments, the deflection of the particle stream is effectuated by non-symmetrical passageways of secondary gas within the nozzle. In other embodiments, the non-symmetrical passageways are attributable to another component such as an air baffle or other form of secondary gas director. other components possess the non-symmetrical. Deflection can occur horizontally (left or right in the plane that is perpendicular to the wire), vertically (up or down relative to the wire), or both horizontally and vertically at the same time.

The system can be implemented in a wide variety of different ways using a wide variety of different components and configurations. Virtually any PTWA system in the prior art can incorporate and benefit by horizontally deflecting the particle stream in certain contexts.

BRIEF DESCRIPTION OF THE DRAWINGS

Many features and inventive aspects of the system are illustrated in the Figures which are described briefly below. However, no patent application can disclose all potential embodiments of an invention through text descriptions or graphical illustrations. In accordance with the provisions of the patent statutes, the principles and modes of operation of the system are explained and illustrated with respect to certain preferred embodiments. However, it must be understood that the components, configurations, and methods described above and below may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. Each of the various elements described in the glossary set forth in Table 1 below can be implemented in a variety of different ways while still being part of the spirit and scope of the invention.

FIG. 1a is block diagram illustrating an example of a particle stream that is created using a prior art PTWA system in which secondary gas is directed to the particle stream in a symmetrical manner. The particle stream in FIG. 1a is not deflected.

FIG. 1b is a block diagram illustrating the example of FIG. 1a, but from a different orientation/point of view. The particle stream in FIG. 1a is not deflected.

FIG. 2a is a block diagram illustrating an example of a particle stream that is being deflected. As a block diagram, FIG. 2a illustrates an example of horizontal deflection in the context of a top view and vertical deflection in the context of a side view. FIG. 2a serves as a direct contrast to a non-deflected particle stream in FIG. 1a.

FIG. 2b is a block diagram that illustrates the example of FIG. 2b, but from a different orientation/point of view. FIG. 2b serves as a direct contrast to the non-deflected particle stream in FIG. 1b.

FIG. 3a is a block diagram illustrating that a nozzle can include one or more nozzle passageways, with each nozzle passageway possessing various attributes such as size, shape, angle, location, and the number of inlets that direct air through the passageway. The non-symmetrical nozzle passageway configuration can be achieved by differentiating one or more such attributes within the passageway configuration.

FIG. 3b is a block diagram illustrating that a system can include one or more passageways, with each passageway possessing various attributes such as size, shape, angle, location, and the number of inlets that direct air through the passageway. The non-symmetrical passageway configuration can be achieved by differentiating one or more such attributes within the passageway configuration. FIG. 3b is similar to FIG. 3a, except that the non-symmetrical configuration originates anywhere within the system, and not necessarily within the nozzle.

FIG. 3c is a face view diagram illustrating an example of a prior art nozzle with a symmetrical nozzle passageway configuration. The nozzle passageways are identical in shape, size, and angle, and the nozzle passageways are positioned in symmetrical locations.

FIG. 3d is a face view diagram illustrating an example of a prior art secondary gas director with a symmetrical passageway configuration. FIG. 3d is similar to FIG. 3c, except that the passageways in FIG. 3d are not necessarily within the nozzle.

FIG. 3e is a face view diagram illustrating an example of a nozzle with a non-symmetrical nozzle passageway configuration in which the sizes of the nozzle passageways are different. Three of the nozzle passageways on the right side of the nozzle are larger than the other nozzle passageways.

FIG. 3f is a face view diagram illustrating an example of a secondary gas director with a non-symmetrical nozzle passageway configuration in which the sizes of the passageways are different. FIG. 3f is similar to FIG. 3e, except that the passageways in the FIG. 3f are not nozzle passageways.

FIG. 3g is a face view diagram illustrating an example of a nozzle with a non-symmetrical nozzle passageway configuration in which the shapes of the nozzle passageways are different.

FIG. 3h is a face view diagram illustrating an example of a secondary gas director with a non-symmetrical passageway configuration in the shapes of passageways are different. FIG. 3h is similar to FIG. 3g, except that the passageways in the FIG. 3h are not nozzle passageways.

FIG. 3i is a face view diagram illustrating an example of nozzle with a non-symmetrical nozzle passageway configuration in which the angles of the nozzle passageways are different.

FIG. 3j is a face view diagram illustrating an example of a secondary gas director with a non-symmetrical passageway configuration in the angles of passageways are different. FIG. 3j is similar to FIG. 3i, except that the passageways in the FIG. 3j are not nozzle passageways

FIG. 3k is cross sectional side view diagram illustrating an example of nozzle with a non-symmetrical nozzle passageway configuration in which the angles of the nozzle passageways are different.

FIG. 3l is a cross sectional side view diagram illustrating an example of a secondary gas director with a non-symmetrical passageway configuration in the angles of passageways are different. FIG. 3l is similar to FIG. 3k, except that the passageways in the FIG. 3l are not nozzle passageways.

FIG. 3m is a face view diagram illustrating an example of a nozzle with a non-symmetrical nozzle passageway configuration in which the non-symmetrical nozzle passageway configuration results from the omission of nozzle passageways at certain otherwise symmetrical locations.

FIG. 3n is a face view diagram illustrating an example of a secondary gas director with a non-symmetrical passageway configuration in which the non-symmetrical passageway configuration results from the omission of passageways at certain otherwise symmetrical locations. FIG. 3n is similar to FIG. 3m, except that the passageways in the FIG. 3n are not nozzle passageways.

FIG. 3o is a face view diagram illustrating an example of a nozzle with a non-symmetrical nozzle passageway configuration in which the nozzle passageways are positioned in non-symmetrical locations.

FIG. 3p is a face view diagram illustrating an example of a secondary gas director with a non-symmetrical passageway configuration in which the passageways are positioned in non-symmetrical locations. FIG. 3p is similar to FIG. 3o, except that the passageways in the FIG. 3p are not nozzle passageways.

FIG. 3q is a face view diagram illustrating an example of a nozzle with a non-symmetrical nozzle passageway configuration in which the configuration includes a single non-symmetrical nozzle passageway.

FIG. 3r is a face view diagram illustrating an example of a secondary air director with a non-symmetrical passageway configuration in which the configuration includes a single non-symmetrical passageway. FIG. 3r is similar to FIG. 3q, except that the passageway in the FIG. 3r are not a nozzle passageway.

FIG. 3s is a side view diagram that corresponds to the example in FIG. 3q. Multiple inlets feeding a single nozzle passageway.

FIG. 3t is a side view diagram that corresponds to the example in FIG. 3r. Multiple inlets feed a single passageway.

FIG. 4 is a flow chart diagram illustrating an example for deflecting a particle stream through a non-symmetrical passageway configuration.

FIG. 5a is top-view diagram illustrating an example a prior art apparatus in which the particle stream is not deflected. This is a view of the particle stream in the horizontal plane

FIG. 5b is a top-view diagram illustrating an example of a particle stream that is deflected in the same direction in which the cathode rotates. As with FIG. 5a, this is a view of the particle stream in the horizontal plane.

FIG. 5c is a top-view diagram illustrating an example of a particle stream that is deflected in the direction opposite to the rotation of the cathode. As with FIGS. 5a and 5b, this is a view of the particle stream in the horizontal plane.

FIG. 6a is a block diagram illustrating an example of the different assemblies that be included in the system, and in which the nozzle within the torch assembly has a non-symmetrical nozzle passageway configuration.

FIG. 6b is a block diagram illustrating an example of the different assemblies that be included in the system, and in which the secondary gas director within the gas assembly has a non-symmetrical passageway configuration.

FIG. 6c is a schematic diagram illustrating an example of the system.

FIG. 6d is an enlarged representation of a portion of FIG. 6b.

The drawings described briefly above can be further understood in accordance with the Detailed Description section set forth below.

DETAILED DESCRIPTION

I. GLOSSARY/TERMINOLOGY

All element numbers referenced in the text below are listed in Table 1 along with an element name and definition/description.

TABLE 1

Element

Number
Element Name
Element Definition/Descriptions

50
Prior Art Apparatus
A prior art PTWA (plasma transferred

wire arc) thermal spraying apparatus

that forms a plasma arc 60 between a

cathode 212 and a free end 370 of a

wire 310.

60
Plasma Arc
An arc of ionized gas forming between a

cathode 212 and a free end 370 of a

wire 310. The plasma arc 60 is

comprised of a jet of very hot plasma

produced from electric current 490

traveling through ionized plasma gas

516 in the space between the cathode

212 and the wire 310.

61
Gap
The space between the cathode 212

and the free end 370 of the wire 310.

The plasma arc 60 is formed in the gap

61.

62
Plasma Plume
The area surrounding a plasma arc 60

where non-atomized particles 72 are

atomized.

64
Zone
An area or location beyond the melting

of the free end 370 of the wire 310. The

zone 64 can also be referred to as a

wire-plasma intersection zone.

66
Vector Forces
Forces pushing particles 70 in the same

direction of the ionized plasma gas 516.

68
Associated Plasma
Plasma that surrounds the plasma

plume 62.

70
Particles or
The system 100 atomizes the particles

Particle Stream
70 in the wire 310 and sprays them

towards a surface 80. The particles 70

projected towards the surface 80 are

originally solid, in the form of the wire

310. A free end 370 of the wire 310 is

melted into non-atomized particles 72

and then atomized into atomized

particles 74 which are then sprayed on

the desired surface 80. The purpose of

the system 100 is to generate a particle

stream 70 of atomized particles 74. As

a practical matter, some quantity of non-

atomized particles 72 will be included in

the particle stream 70. The further from

optimal the operation of the system 100

becomes, the greater the ratio of non-

atomized particles 72 to atomized

particles 74.

71
Spit
A more extreme example of non-

atomized particles 72 in the particle

stream 70 that is visible to the human

eye. The existence of spit 71 in the

particle stream 70 means that operation

of the system 100 is likely not

satisfactory. Spit 71 is a manifestation

of a system 100 in which the various

processes and components of the

system 100 are not configured and

synchronized for the system 100 to

function in a desirable fashion.

72
Non-Atomized Particles
Particles 70 from the wire 310 that have

been melted or partially melted, but not

fully atomized. In the theoretically

optimal and aspirational operation of the

system 100, the particle stream 70 is

comprised entirely of atomized particles

74. Realistically however, there will also

be non-atomized particles 72 in the

particle stream 70. As the operation of

the system 100 falls further away from

optimal, the non-atomized particles 72

can be in the form of spit 71. Non-

atomized particles 72 can also often be

referred to as molten metal particles

since at the applicable temperature, the

metal material from the wire 310 will be

in a molten or at least substantially

molten form.

74
Atomized Particles
Particles 70 from the wire that are in a

sufficiently fine form as to be suitable for

spraying on the surface 80 of the

substrate 84.

76
Center Line
A geometric line through the center of

the particle stream that is equidistant

from the sides of the particle stream 70.

When the particle stream 70 is not a

deflected particle stream 90, the center

vector 78 is in line with the center line

76. When the particle stream 70 is a

deflected particle stream 90, the center

line 76 is deflected relative to the center

vector 78.

78
Center Vector
Typically, the center vector 78 is

perpendicular to the wire 310 and in line

with the opening 224. When the particle

stream 70 is not a deflected particle

stream 90, the center vector 78 is in line

with the center line 76. The center

vector 78 is the same regardless of

whether the particle stream 70 is or is

not deflected.

80
Surface
The exterior face or boundary of the

substrate 84 which is being sprayed with

particles 70 from the system 100.

82
Deposit
In a properly functioning system 100,

the deposit 82 is the buildup of atomized

particles 74 sprayed onto the surface 80

by the system 100 or apparatus 110.

Realistically, the deposit 82 is likely to

include some quantity of non-atomized

particles 72. A deposit 82 of spit 71 is

typically unacceptable.

84
Substrate
The material being sprayed on by the

system 100 or apparatus 110. The

deposit 82 is formed from spraying the

particles 70 onto the surface 80 of the

substrate 84.

90
Deflected Particle Stream
A particle stream 70 that has a center

line 76 that is not in line with center

vector 78. A deflected particle stream

90 has a deflection angle that is not

zero. A deflected particle stream 90 can

be deflected horizontally (e.g. horizontal

deflection 91), vertically (e.g. vertical

deflection 92), or both vertically and

horizontally at the same time.

91
Horizontal Deflection or a
Deflection of the particle stream 70 that

Horizontally Deflected Particle
occurs in the horizontal plane, the plane

Stream
that is perpendicular to the wire 310 and

in line with the opening 224. The

deflection direction 94 is to the left or to

the right relative to a non-deflected

particle stream 70.

92
Vertical Deflection or a Vertically
Deflection of the particle stream 70 that

Deflected Particle Stream
occurs in the vertical plane, the plane

containing the line of the wire 310 and

the line of the opening 224 of the nozzle

220. The deflection direction 94 is up or

down relative to a non-deflected particle

stream 70.

94
Deflection Direction
The direction in which a particle stream

70 is deflected.

96
Deflection Angle
An angular measurement of the

deflection in a center line 76 from the

center vector 78.

97
Horizontal Deflection Angle
The deflection angle 96 with respect to

horizontal deflection 91.

98
Vertical Deflection Angle
The deflection angle 96 with respect to

vertical deflection 92.

100
Plasma Arc Thermal Spray
A PTWA (plasma transferred wire arc)

System Or
system for projecting (i.e. spraying)

System
atomized particles 74 onto a surface 80

of a substrate 84. The system 100 can

utilize a cartridge 560 in which a plasma

gas director 571 is integral with a

secondary gas director 576. The PTWA

system 100 can be referred to simply as

the system 100. The system 100 can

be implemented in a wide variety of

embodiments, including a variety of

different apparatuses 110 and methods

900.

110
Plasma Arc Thermal Spray
A plasma arc thermal spray system 100

Apparatus
that is implemented in the form of a

device that is at least partially

constrained within a housing.

200
Torch Assembly
An aggregate configuration of

subassemblies, components, and parts

that provide for the creation and

sustaining of a plasma arc 60 from the

cathode 212 to a free end 370 of a wire

310. The inputs for the torch assembly

200 are electricity 490 from a power

delivery assembly 400, a wire 310 from

a wire delivery assembly 300, and a gas

510 from a gas delivery assembly 500.

202
Torch Body
The torch assembly 200 enclosed in an

exterior surface.

206
Rotational Centerline
A central axis around which the cathode

212 revolves around in an orbit 280 that

is typically at least substantially circular

in shape. In some embodiments, the

rotational centerline 206 is the position

of the wire 310. In other embodiments,

there is an offset between the position of

the wire 310 and the rotational

centerline 206 (see U.S. Pat. No.

8,581, 138 which is hereby incorporated

by reference in its entirety).

210
Cathode Subassembly
An aggregate configuration of

components and parts that support the

functionality of the cathode 212 within

the torch assembly 200.

212
Cathode
A negatively charged electrode used to

form the plasma arc 60.

214
Cathode Holder
A structure that secures the position of

the cathode 212 relative to the other

components of the torch assembly 200

and the various inputs delivered to the

torch assembly 200.

220
Nozzle
A projecting spout through which

something flows in an outward direction.

222
Plasma Nozzle
A nozzle 220 through which plasma gas

512 exits.

224
Constricting Orifice or Opening
An opening or passageway within the

nozzle 220 that narrows as the plasma

gas 512 travels through it. The

constricting orifice 224 can be referred

to simply as the opening 224. The

opening 230 is typically perpendicular to

the surface 80 being sprayed and in line

with the particle stream 70, but the

system 100 can be implemented such

that the opening 230 is not

perpendicular to the surface 80

226
Annulus nozzle
A plasma nozzle 222 that has one

nozzle passageway 240 with multiple

inlets 245. An annulus nozzle 226 is

typically cone shaped.

240
Nozzle Passageway
A passageway 540 or a portion thereof

that exists in the nozzle 220 through

which the secondary gas 518 passes

through the nozzle 220 to reach the

particle stream 70 that is directing the

secondary gas 518. Attributes of a

nozzle passageway 240 that can result

in a non-symmetrical nozzle

passageway configuration 249 include

but are not limited to size 241, shape

242, angle 243, location 244, and inlet

245.

241
Passageway Size or Size
A quantitative metric, such as distance,

area, or volume that describes the

magnitude of the nozzle passageway

240. Some embodiments of the system

100 may utilize differences in

passageway sizes 241 to create a non-

symmetrical nozzle passageway

configuration 249.

242
Passageway Shape or Shape
Geometric information about a nozzle

passageway 240 that remains when

location, scale, orientation, and

reflection are removed. Some

embodiments of the system 100 may

utilize differences in passageway

shapes 242 to create a non-symmetrical

nozzle passageway configuration 249.

243
Passageway Angle or Angle
The angle at which a passageway 240

directs secondary gas 518 to the particle

stream 70. Some embodiments of the

system 100 may utilize differences in

passageway angles 243 to create a

non-symmetrical nozzle passageway

configuration 249. The angle 243 is

measured relative to a center vector 78

in the nozzle 220.

244
Passageway Location or
A position of a passageway 240 on the

Location
nozzle 220. Some embodiments of the

system 100 may utilize differences the

layout of passageway locations 244 to

create a non-symmetrical nozzle

passageway configuration 249.

Symmetrical locations 244 are even

spaced around a hypothetical center

point in the nozzle 220.

245
Passageway Inlet or Inlet
An entry opening into a passageway

240 in the nozzle 220. In many

embodiments, each nozzle passageway

240 will have only one inlet 245, but it is

possible for a single nozzle passageway

240 to have 2 or more inlets 245.

249
Non-Symmetrical Nozzle
A configuration of nozzle passageways

Passageway Configuration
240 that causes the particle stream 70

to be a deflected particle stream 90.

The absence of symmetry can be

achieved in a variety of different ways,

such as through a difference in nozzle

passageway size 241, nozzle

passageway shape 242, nozzle

passageway angle 243, and/or through

a non-symmetrical arrangement of

nozzle passageway locations 244 (such

as non-symmetrical nozzle passageway

locations 244 or symmetrical locations

244 with one or more locations devoid of

nozzle passageways 240). In many

embodiments of the system 100, the

non-symmetrical structure of a non-

symmetrical passageway configuration

549 will be located within the nozzle 220

as a non-symmetrical nozzle

passageway configuration 249.

280
Orbit or Rotation
A pathway around a rotational centerline

206 that is typically at least substantially

circular in shape. Much of the literature

on prior art PTWA 50 describes this

movement as a rotation around the

rotational centerline 206 by the cathode

212.

282
Radial Distance
The distance between a cathode 212 (in

an orbit 280 around the free end 370 of

a wire 210) and the free end 370 of the

wire around which the cathode 212

moves. The system 100 can be

implemented such that the radial

distance can be less than about 35 mm,

or even less than about 25 mm.

290
Over Spray Shield
A component that blocks the spray 70

from being directed to an undesirable

location.

300
Wire Delivery Assembly
An aggregate configuration of

components that provide for the

movement of the wire 310 towards the

position where a free end 370 of the

wire 310 is positioned for the plasma arc

60. The wire delivery assembly 300 can

also be referred to as a wire assembly

300.

310
Wire
A material in the shape of a slender,

string-like piece or filament. The wire

310 is comprised of the matter from

which the atomized particles 74 are

derived and directed to the surface 80 of

the substrate 84. The wire 310 is

typically made of metal, but can also be

made of ceramic in a metal sheath

which is known as a chord wire.

320
Feedstock
A portion of the wire 310 that is the

opposite end to the free end 370.

Feedstock 320 can also be referred to

as the wire base or wire supply.

Feedstock 320 is the portion of the wire

310 that is not yet within the rollers 340,

the contact tip 422, or the guide tip 330.

The feedstock 320 is where the supply

of wire 310 is positioned and stored until

the speed-controlled motor 350 moves

the particular portion of the wire 310.

330
Guide Tip
A hollow structure through which the

wire 310 moves. The guide tip 330 is

often the final structure that helps

position the wire 310 and more

specifically the free end 370 of the wire

310 at the desired position for the

creation and sustaining of a plasma arc

60. This is sometimes called a wire

guide 330.

332
Guide Tip Block
This structure provides support for the

guide tip 330. It is typically contained

within an insulating object 430.

340
Rollers
Rotating structures that are at least

substantially cylindrically shaped.

Rollers 340 are powered by the speed-

controlled motor 350. Rollers 340 move

the wire 310 towards the guide tip 330.

350
Speed-Controlled Motor
An engine that moves a free end 370 of

the wire 310 (with the rest of the wire

310 following) through the wire delivery

assembly 300 to the desired position for

the plasma arc 60. The speed-

controlled motor 350 moves the wire

310 by powering the rollers 340.

352
Wire Speed
The velocity at which the wire 370

moves towards the gap 61. Wire speed

352 is controlled primarily by the motor

350.

370
Free End
An end portion of the wire 310 that is

melted and atomized within a proper

plasma arc 60. The free end 370 of the

wire 310 is opposite to the feedstock

320 end. The free end 370 of the wire

310 includes an end tip 371 as well as

the portions/lengths of the wire prior to

the end tip 371. The free end 370 of the

wire 310 is from the end tip 371 to

portions of the wire 310 that have just

passed through the guide tip 330.

371
End Tip
The portion of the free end 370 that is

the precise end position.

400
Power Delivery Assembly
An aggregate configuration of

subassemblies, components, and parts

that collectively provide the electricity

490 used to sustain the plasma arc 60.

In most embodiments of the system

100, the power delivery assembly 400

provides for supplying electricity 490 in

the form of direct current (DC) electricity

490. The power delivery assembly 400

can also be referred to as a power

assembly 400.

410
Power Supply
A device that provides the electricity 490

for forming the plasma arc 60 from the

cathode 212 to the free end 370 of the

wire 310.

412
DC Power Source
A power supply 410 that provides for

directing electricity 490 in the form of

direct current (DC) along the electrical

pathway 492.

420
Lead/Contact
An electrical connection comprising a

length of wire or a metal conductive pad.

The power delivery assembly 400 can

utilize a wide variety of different

leads/contacts 420 to direct electricity

490 throughout the power delivery

assembly 400.

422
Contact Tip
A lead 420 in direct physical contact

with the wire 310 that provides for

routing electricity 490 to the wire 310. In

some embodiments, the contact tip 422

can be made up of two or more pieces

such as 422A and 422B, held in spring

or pressure load contact with the wire

310 by a rubber ring 432 or other similar

structure.

430
Insulating Object
A structure that does not conduct

electricity 490. The system 100 may

use various insulating objects 430 to

direct electricity 490 through the desired

electrical pathway 492.

432
Rubber Ring
An insulating object 430 typically used

to hold the contact tip 422 together with

the wire 310 so that the portion of the

wire 310 in contact with the contact tip

422 to the free end 370 becomes part of

the electrical pathway 492.

434
Insulating Block
An insulating object 430 that insulates

the portion of the wire 310, contact tip

422, and free end 370 from the torch

components with the same electrical

potential as the cathode 212.

450
Open Circuit
An unintentional gap in the electrical

pathway 492 that can negatively impact

the performance of the system 100. An

open circuit 450 can also be referred to

as a bad contact 450.

490
Electricity
A form of energy resulting from the

existence of charged particles (such as

electrons or protons), either statically as

an accumulation of charge or

dynamically as a current. Electricity 492

is a necessary input for creating and

sustaining a plasma arc 60.

492
Circuit or Electrical Pathway
A route that the electricity 490 forming

the plasma arc 60 travels from the

power supply 410 to the plasma arc 60

and back again.

500
Gas Delivery Assembly
An aggregate configuration of

subassemblies, components, and parts

that collectively provide the gas 510 or

gasses 510 used to sustain the plasma

arc 60. The gas delivery assembly 500

can also be referred to as a gas

assembly 500.

510
Gas
A non-solid, non-liquid and non-ionized

material supplied to the torch assembly

200.

512
Plasma Gas
A gas 510 that will become ionized to

create and sustain the plasma arc 60.

An example of a suitable plasma gas

512 is Ar—H2 65/35, but other plasma

gasses 512 known in the prior art can

be used by the system 100. In some

instances, the secondary gas 518 can

be used as the plasma gas 512.

516
Ionized Plasma Gas
Plasma gas 512 in a sufficiently heated,

ionized, and in a high velocity state

(often supersonic) that it is suitable for

atomizing the material in the free end

370 of the wire 310.

518
Secondary Gas
A gas 510 that is used to direct the

particle stream 70 originating from the

free end 370 the wire 310 in the desired

direction. The secondary gas 518 can

in some embodiments be used as the

plasma gas 512. A secondary gas 518

is typically introduced into the gas

manifold 550. The flow of the secondary

gas 518 is typically higher that the flow

of the plasma gas 512. Secondary gas

518 is used to further atomize and

accelerate the particles 70. A common

example of a secondary gas 518 is air,

but there are many different secondary

gases 518 known in the prior art that

can be utilized by the system 100.

520
Gas Source
A subassembly or component that

supplies one or more gases 510 to the

system 100 or apparatus 110.

522
Primary Gas Source/Plasma
The gas source 520 for plasma gas 512.

Gas Source

524
Secondary Gas Source
The gas source 520 for secondary gas

518.

530
Gas Port
A passageway through which gas 510

can travel and is directed to travel from

one location within the system 100 to

another location. A common example of

a gas port 530 is an opening in the

cathode holder 214 or torch body 202

through which gas 510 exits. The gas

port 530 allows for the delivery of gas

510 to the cathode 212. Gas 510

travelling to the cathode 212 through the

gas port 530 is an important input for the

creation of the plasma arc 60.

532
Plasma Gas Port
A port 530 that provides for the delivery

of plasma gas 512 to the cathode holder

214.

534
Secondary Gas Port
A port 530 that provides for the delivery

of secondary gas 518 to the gas

manifold 550.

536
Insulator Block Gas Port
A port 530 within the insulator block 434

that provides for a small amount of

secondary gas 518 to be directed

through the insulator block 424 to

facilitate the removal of heat from the

insulator block 434.

540
Passageway
A passageway in the system 100

through which the secondary gas 518

passes through the system 100 to reach

the particle stream 70 that is directing

the secondary gas 518. A passageway

540 can exist within a nozzle 220 (a

nozzle passageway 240) or outside the

nozzle 220. A bore 556 is an example

of a passageway 540 that exists outside

the nozzle 220.

541
Passageway Size or Size
A quantitative metric, such as distance,

area, or volume that describes the

magnitude of the passageway 540.

Some embodiments of the system 100

may utilize differences in passageway

sizes 541 to create a non-symmetrical

passageway configuration 549.

542
Passageway Shape or Shape
Geometric information about a

passageway 540 that remains when

location, scale, orientation, and

reflection are removed. Some

embodiments of the system 100 may

utilize differences in passageway

shapes 542 to create a non-symmetrical

passageway configuration 549.

543
Passageway Angle or Angle
The angle at which a passageway 540

directs secondary gas 518 to the particle

stream 70. Some embodiments of the

system 100 may utilize differences in

passageway angles 543 to create a

non-symmetrical passageway

configuration 549. The angle 543 is

measured relative to the center vector

78.

544
Passageway Location or
A position of a passageway 540. Some

Location
embodiments of the system 100 may

utilize differences the layout of

passageway locations 544 to create a

non-symmetrical passageway

configuration 549. Symmetrical

locations 544 are evenly spaced around

a hypothetical center point.

545
Passageway Inlet or Inlet
An entry opening into a passageway

540. In many embodiments, each

passageway 540 will have only one inlet

545, but it is possible for a single

passageway 540 to have 2 or more

inlets 545.

549
Non-Symmetrical Configuration
A configuration of passageways 540

that causes the particle stream 70 to be

a deflected particle stream 90. The

absence of symmetry can be achieved

in a variety of different ways, such as

through a difference in passageway size

541, passageway shape 542,

passageway angle 543, and/or through

a non-symmetrical arrangement of

passageway locations 544 (such as

non-symmetrical passageway locations

544 or symmetrical locations 544 with

one or more locations devoid of

passageways 540).

550
Gas Manifold
A cavity or chamber formed between a

secondary gas director 576 and the

torch body 202. The gas manifold 550

can also be referred to as a first

manifold 550.

554
Second Manifold
A cavity or chamber that secondary gas

518 is directed to after the initial gas

manifold 550. Secondary gas 518

moves from the first manifold 550 to the

second manifold 54 through bores 556

connecting the two chambers.

556
Bores
A passageway 540 that is positioned

outside the nozzle 220.

570
Gas Director
A device that directs the flow of a gas

510 in the system 100. A gas director

570 is a type of gas port 530 but not

every gas port 530 is a gas director 570.

A gas director 570 does more than

provide a passageway for the

movement of gas 510. A gas director

570 distributes gas 510. A gas director

570 is analogous to a sprinkler head

that distributes water on a lawn. In

contrast, a gas port 530 that is not a gas

director 570 is analogous to a mere pipe

through which water is merely

transported. A gas director 570 shapes

the distribution of the respective gas 510

to facilitate the conditions for an

effective plasma arc 60. Examples of

gas directors 570 can include but are

not limited to plasma gas directors 571

and secondary gas directors 576. There

are a variety of different gas directors

570 and resulting gas flows that are

known in the prior art. The system 100

can be implemented using any of such

gas directors 570 and flows.

571
Plasma Gas Director
A gas director 570 that directs plasma

gas 512 towards the cathode 212.

Examples of plasma gas directors 571

can include but are not limited to swirl

rings 574, laminar tubes 573, and

turbulent openings 572.

572
Turbulent Opening
An example of a plasma gas director

571 that is not swirl-based. The plasma

gas 512 in a turbulent opening 572

involves a velocity that fluctuates

irregularly through the result of continual

mixing.

573
Laminar Tube
An example of a plasma gas director

571 that is not swirl-based. The plasma

gas 512 in laminar tube 573 involves

plasma gas 512 that moves at the same

velocity entering the tube 573 as it does

leaving the tube 573. A cartridge 560

can include multiple laminar tubes 573

used to arrange the delivery of plasma

gas 512 to the cathode 212.

574
Swirl Ring
An example of a plasma gas director

571 that directs the plasma gas 512 in a

swirling motion towards the cathode

212. The system 100 can include one

or more swirl rings 574 configured in

various positions around the cathode

212. There are numerous swirl rings

574 known in the prior art.

576
Secondary Gas Director
A gas director 570 used to direct a

secondary gas 518 towards the particle

stream 70. The most common example

of a secondary gas director 576 is an air

baffle 578.

578
Air Baffle Or
An example of a secondary gas director

Baffle Plate
576.

590
Plasma Chamber
The area around the cathode 212 where

plasma gas 512 is ionized to form the

arc 60.

600
Sensor Assembly
An optional assembly within the system

100 that can be used to capture sensor

readings that relate to operations of the

system. For example, electrical

measurements captured by sensors can

be used to identify certain undesirable

conditions before the symptoms of those

conditions are readily ascertained by

human observers. Please see the patent

application titled “SYSTEM,

APPARATUS, AND METHOD FOR

MONITORED THERMAL SPRAYING”

(Serial Number 15/191,497 that was

filed on Jun. 23, 2016), the contents of

which are hereby incorporated by

reference in their entirety.

700
IT Assembly
An optional assembly within the system

100 that can be used process

information captured by the sensor

assembly 600. Such an assembly can

proactively identify undesirable

operating conditions at an early stage so

that they can be corrected.

900
Method
A process of steps for detecting out of

tolerance operating conditions 800 in

the thermal spray process and

selectively generating a response 770.

II. OVERVIEW

The system 100 can be implemented and used with respect to virtually any prior art PTWA apparatus 50. Implementation of the system 100 involves will often involve use of a nozzle 220 that includes a non-symmetrical nozzle passageway configuration 249. However, other components of the system 100 such as an air baffle 578 or some other secondary gas director 576 can be implemented to possess the structural attributes effectuating the non-symmetrical passageway configuration 549.

The non-symmetrical nature of a non-symmetrical passageway configuration 549 can be grounded in a variety of different attribute configurations. By way of example, such a configuration can result from even one of the following attributes:

- 1. Two or more passageways 540 are of a different size 541.
- 2. Two or more passageways 540 are of a different shape 542.
- 3. Two or more passageways 540 are positioned at different angles 543 relative to a center vector.
- 4. At least one passageway 540 is omitted at a symmetrical location 544.
- 5. At least one passageway 540 is positioned a non-symmetrical location 544

The deflection of particle stream 70 can also be influenced by other factors acting in concert with a non-symmetrical passageway configuration 549, such as the pressure, quantity, temperature, and density of the secondary gas 518.

Whether the source of non-symmetry resides within the nozzle 220, outside the nozzle 220, or both within and outside of the nozzle 220, such a non-symmetrical configuration 549 can be implemented to deflect the particle stream 70 horizontally 91 and/or vertically 92. Horizontal deflection 91 in the direction that is opposite to the rotational movement 280 of the cathode 212 as it rotates around the wire 310 can be particularly desirable, but horizontal deflection 91 with the direction in which the cathode 212 rotates around the wire 312 may desirable in certain contexts.

Secondary gas 518 (typically air, but other secondary gases 518 are known in the prior art) is directed towards the particle stream 70 to shape and direct the particle stream The particle stream 70 is created by the plasma arc 70 across a gap 61 between the cathode 212 and the free end 370 of the wire 310. In the prior art, the secondary gas 518 is directed in a symmetrical manner towards to the particle stream 70. This results in a particle stream 70 that is highly symmetrical and collimated. The spray pattern in such a particle stream 70 can be relatively narrower in comparison to the spray pattern resulting from a non-symmetrical passageway configuration 549.

Particle streams 70 that are not deflected have a center line 76 that is horizontally perpendicular to the free end of the wire 370 and in line with the center vector 78. Such a center line 76 protrudes mostly straight out from the plasma arc 60, from the center point in the opening 224 of the nozzle 220 along the center vector 78. A particle stream that is deflected can be referred to as a deflected particle stream 90.

Deflection can occur in a vertical up/down direction (which is referred to as vertical deflection 92), a horizontal left/right direction (which is referred to as horizontal deflection 91), or in both directions simultaneously. It is believed that horizontal deflection 91 is particularly useful, and the horizontal deflection 91 is against the direction of at which a cathode 212 rotates around the free end 370 of the wire 310 is potentially more useful than horizontal deflection 91 that is in the same direction in which the cathode 212 rotates.

A deflected particle stream 90 differs in several respects from a non-deflected particle stream 70. A deflected particle stream 90 increases the porosity of the coating on the surface 80 being sprayed. Such a particle stream 90 is less collimated, with a wider and non-symmetrical spay pattern. Also, by creating a less collimated spray pattern there is less localized heating of the surface 80. Not all of the particles in the particle stream 90 will adhere to the surface 80. Particles that do not adhere will be deflected and/or splash off the surface 80. With a deflected particle stream 90 these particles not adhering to the surface 80 are less likely to build up on the face of the nozzle 220. In addition, by performing horizontal deflection 91 as opposed to vertical deflection 92, there will be less buildup of these particles not adhering to the surface on the torch body 202 above the nozzle 220.

FIG. 1a is block diagram illustrating an example of a particle stream 70 that is created using a prior art PTWA system 50 in which secondary gas 518 is directed to the particle stream 70 in a symmetrical manner. FIG. 1b is a block diagram illustrating the example of FIG. 1a, but from a different orientation/point of view. For example, if FIG. 1a is taken as a top view, then FIG. 1b is a view from looking down the centerline of the opening 224 in the nozzle 220. If FIG. 1a is a side view, then FIG. 1b is a view from looking at the centerline of the opening 224 in the nozzle 220.

FIG. 2a is a block diagram illustrating an example of a particle stream 70 that is being deflected. As a block diagram, the illustration of FIG. 2a is capable of illustrating an example of horizontal deflection 91 (deflection in a right/left direction) in the context of a top view or vertical deflection 92 (deflection in an up/down direction) in the context of a side view. FIG. 2a serves as a direct contrast to a non-deflected particle stream in FIG. 1a. FIG. 2b is a block diagram that illustrates the example of FIG. 2a, but from a different orientation/point of view. Vertical deflection 92 is illustrated if FIG. 2a is taken as a side view, while horizontal deflection 91 is illustrated if FIG. 2a is taken as a top view. FIG. 2b is a similar view to FIG. 1b, except that in FIG. 1b there is no deflection and in FIG. 2b there is deflection.

In the context of horizontal deflection, the deflection angle 79 is an angle in the left/right plane. The deflection angle 79 can be less than 5 degrees, up to 10 degrees, in excess of 10 degrees, or even in excess of 20 degrees depending on the specific nature of the material making up the surface 80 to be treated with the particle stream 70.

In the context of vertical deflection, the deflection angle 79 is an angle in the up/down plane. The deflection angle 79 can be less than about 5 degrees, up to about 10 degrees, in excess of about 10 degrees, or even in excess of about 20 degrees depending on the specific nature of the material making up the surface 80 to be treated with the particle stream 70.

III. NON-SYMMETRICAL PASSAGEWAY CONFIGURATION

The system 100 can implement non-symmetrical passageway configuration 549 that includes one or more passageways 540 in a variety of different ways. In many embodiments, the non-symmetrical passageway configuration 549 is a non-symmetrical nozzle passageway configuration 249, but the non-symmetry can also be based on the structure of the secondary gas director 576, such as an air baffle 578.

Attributes of the nozzle 220 and/or secondary gas director 576 can result in a deflected particle stream 90 without changing the orientation of the nozzle 220 or the orientation of the wire 310 that is used to form the plasma arc 60.

Any non-symmetrical passageway configuration 549 of one or more passageways 540 in the system 100 can potentially result in the directing of secondary gas 518 in a non-symmetrical manner such that the particle stream 70 is a deflected particle stream

A. Passageway Attributes

FIG. 3a is a block diagram illustrating that a nozzle 220 can include one or more nozzle passageways 240, with each nozzle passageway 240 possessing various attributes such as size 241, shape 242, angle 243, location 244, and the number of inlets 245 that direct secondary gas 518 through the nozzle passageway 240. The non-symmetrical nozzle passageway configuration 249 can be achieved by differentiating one or more such attributes within the nozzle passageway configuration 249. By way of example, the different nozzle passageways 240 can be identical in all respects except for size 241 and the resulting configuration 249 is non-symmetrical causing the resulting particle stream 70 to be a deflected particle stream 90. Differentiation is only required with respect to one attribute is required for a non-symmetrical nozzle passageway configuration 249, but multiple types of nozzle passageway 240 attributes can be used simultaneously to trigger the desired deflection in the particle stream 70.

FIG. 3b is a similar but more generalized block diagram compared to FIG. 3a, with FIG. 3b illustrating that the non-symmetrical nature of the non-symmetrical passageway can exist outside the nozzle 220 and elsewhere in the system 100. A system 100 can include one or more passageways 540, with each passageway 540 possessing various attributes such as size 541, shape 542, angle 543, location 544, and the number of inlets 545 that direct secondary gas 518 through the passageway 540. The non-symmetrical passageway configuration 549 can be achieved by differentiating one or more such attributes within the passageway configuration. By way of example, the different passageways 549 can be identical in all respects except for size 541 and the resulting configuration 549 is non-symmetrical causing the resulting particle stream 70 to be a deflected particle stream 90. Differentiation is only required with respect to one attribute is required for a non-symmetrical passageway configuration 549, but multiple types of passageway 540 attributes can be used simultaneously to trigger the desired deflection in the particle stream 70.

B. Prior Art

FIG. 3c is a face view diagram illustrating an example of a nozzle 220 in the prior art where the configuration of nozzle passageways 240 are symmetrical. Such a configuration of nozzle passageways 240 will result in a particle stream 70 that is not deflected.

FIG. 3d is face view diagram illustrating an example of a prior art secondary gas director 576 with passageways 540 in a symmetrical configuration. Such a configuration of passageways 540 will result in a particle stream 70 that is not deflected.

C. Size

FIG. 3e is a face view diagram illustrating an example of a nozzle 220 with a non-symmetrical nozzle passageway configuration 249 in which the sizes 241 of the nozzle passageways 240 are different. More specifically, the three nozzle passageways 240 on the right side of the diagram are larger than the other nozzle passageways 240 in the figure. The nozzle passageway attributes of shape 242 and angle 243 are identical, and the locations 244 are symmetrical, yet the differences in size 241 result in a non-symmetrical nozzle passageway configuration 249.

FIG. 3f is a face view diagram illustrating an example of a secondary gas director 576 with a non-symmetrical passageway configuration 549 in which the sizes 541 of the passageways 540 are different. More specifically, the three passageways 540 on the right side of the diagram are larger than the other passageways 540 in the figure. The passageway attributes of shape 542 and angle 543 are identical, and the locations 544 are identical, yet the differences in size 541 result in a non-symmetrical passageway configuration 549.

D. Shape

FIG. 3g is a face view diagram illustrating an example of a nozzle 220 with a non-symmetrical nozzle passageway configuration 249 in which the shapes 242 of the nozzle passageways 240 are different. The nozzle passageway attributes of size 241 and angle 243 are identical, and the locations 244 are symmetrical, yet the differences in shape 242 result in a non-symmetrical nozzle passageway configuration 249.

FIG. 3h is a face view diagram illustrating an example of a secondary gas director 576 with a non-symmetrical passageway configuration 549 in which the shapes 542 of the passageways 540 are different. The passageway attributes of size 541 and angle 543 are identical, and the locations 544 are symmetrical, yet the differences in shape 542 result in a non-symmetrical passageway configuration 549.

E. Angle

FIG. 3i is a face view diagram illustrating an example of a nozzle 220 with a non-sym metrical nozzle passageway configuration 249 in which the angles 243 of the nozzle passageways 240 are different. The nozzle passageway attributes of size 241, and shape 242 are identical, and the locations 244 are symmetrical, yet differences in the angles 243 result in a non-symmetrical nozzle passageway configuration 249.

FIG. 3j is a face view diagram illustrating an example of a secondary gas director 576 with a non-symmetrical passageway configuration 549 in which the angles 543 of passageways 540 are different. The passageway attributes of size 541 and shape 542 are identical, and the locations 544 are symmetrical, yet differences in the angles 543 result in a non-symmetrical passageway configuration 549.

FIG. 3k is cross sectional side view diagram illustrating an illustrating an example of nozzle 220 with a non-symmetrical nozzle passageway configuration 249 in which the angles 243 of the nozzle passageways 240 are different.

FIG. 3l is a cross sectional side view diagram illustrating an example of a secondary gas director 576 with a non-symmetrical passageway configuration 549 in the angles 543 of passageways 540 are different.

F. Locations

Non-symmetry in locations 544 can be achieved through the omission of one or more passageways 540 in an otherwise symmetrical configuration or by having at least one passageway 540 at a non-symmetrical location 544.

1. Omission

FIG. 3m is a face view diagram illustrating an example of a nozzle 220 with a non-symmetrical nozzle passageway configuration 249 in which the non-symmetrical nozzle passageway 249 configuration results from the omission of nozzle passageways 240 at certain otherwise symmetrical locations 244. The various nozzle passageways attributes of size 241, shape 242, and angle 243 are identical. In FIG. 3m, there are three adjacent vacant locations 244, but any combination of one or more vacant locations 244 can be used to trigger the non-symmetrical flow of air 518 to deflect the particle stream 70.

FIG. 3n is a face view diagram illustrating an example of a secondary gas director 576 with a non-symmetrical passageway configuration 549 in which the non-symmetrical passageway configuration 549 results from the omission of passageways 540 at certain otherwise symmetrical locations 544. The various passageways attributes of size 541, shape 542, and angle 543 are identical. In FIG. 3n, there are three adjacent vacant locations 544, but any combination of one or more vacant locations 544 can be used to trigger the non-symmetrical flow of air 518 to deflect the particle stream 70.

2. Non-Symmetrical Location

FIG. 3o is a face view diagram illustrating an example of a nozzle 220 with a non-symmetrical passageway configuration 249 in which at least one nozzle passageway 240 is positioned in a non-symmetrical location 244. The nozzle passageways 240 are otherwise identical in their attributes.

FIG. 3p is a face view diagram illustrating an example of a secondary gas director 576 with a non-symmetrical passageway configuration 549 in which at least one passageway 540 is positioned in a non-symmetrical location 544. The passageways 540 are otherwise identical in their attributes.

G. Inlets

FIG. 3q is a face view diagram illustrating an example of a nozzle 220 with a non-symmetrical nozzle passageway configuration 249 in which the configuration includes a single non-symmetrical nozzle passageway 240. The lack of symmetry is technically the result of the shape 241 of the passageway 240. FIG. 3s is a side view diagram that corresponds to the example in FIG. 3q. Multiple inlets 245 feed a single nozzle passageway 240. Different embodiments of the system 100 can involve one or more nozzle passageways 240 with different numbers of inlets 245. In many embodiments, each nozzle passageway 240 will have only one inlet 245.

FIG. 3r is a face view diagram illustrating an example of a secondary air director 576 with a non-symmetrical passageway configuration 549 in which the configuration includes a single non-symmetrical passageway 540. FIG. 5r is similar to FIG. 3q except that the passageway 540 in FIG. 3r is not within the nozzle 220. FIG. 3t is a side view diagram that corresponds to the example in FIG. 3r.

FIG. 3s is a side view diagram that corresponds to the example in FIG. 3q. Multiple inlets 245 feed a single nozzle passageway 240.

FIG. 3t is a side view diagram that corresponds to the example in FIG. 3r. Multiple inlets 545 feed a single passageway 540.

IV. PROCESS FLOW VIEW

FIG. 4 is a flow chart diagram illustrating an example for a method 900 for deflecting a particle stream 70 through the use of a non-symmetrical passageway configuration 549. The configuration 549 typically includes multiple passageways 540 that are differentiated on the basis of size 541, shape 542, angle 543, or locations 544. Differentiation based on location 544 can implemented through symmetrical locations 544 where one or more locations 544 are vacant. In other embodiments, the locations 544 are simply not equally spaced. In many instances, the passageways 540 will be nozzle passageways 240, and the non-symmetrical passageway configuration 549 will be the result of a non-symmetrical nozzle passageway configuration 249.

Some embodiments of the method 900 can involve a single passageway 540 that is non-symmetrical on the basis of shape 541, size 542, or angle 543 with respect to different portions of the passageway 540 (the passageway 540 is an aggregated single passageway that is fed through one or more inlets 545).

At 910, plasma gas 512 is moved towards the cathode 212. Plasma gas 514 is necessary for creating a plasma arc 920 necessary to atomize the free end 370 of the wire 310.

At 920, the plasma arc 60 is ignited. This is sometimes done across the gap 61 between the cathode 212 and the wire 310. The plasma arc 60 can also be ignited between the cathode 212 and the nozzle 220 and then the plasma arc 60 can be transferred to the wire 310. The required inputs for the plasma arc 60 are plasma gas 514 and electricity 490.

At 930, a particle stream 70 is created by the melting/atomizing of the free end 370 of the wire 310 by the plasma arc 60.

At 940, the particle stream 70 is deflected with secondary gas 518 such as air so that the particle stream 70 is a deflected particle stream 70. Deflection can be horizontal deflection 91 (left/right), vertical deflection 92 (up/down), or both at the same time. Deflection can be implemented through a wide range of different non-symmetrical passageway configurations 549 based on differences in one or more configuration attributes. The magnitude of the deflection of the particle stream 70 can also be influenced by the secondary gas pressure, temperature, and other factors.

V. HORIZONTAL DEFLECTION RELATIVE TO A ROTATING CATHODE

Deflection is particularly interesting when it is done horizontally on a system 100 that involves a cathode 212 that rotates around a wire 310 in a trajectory that can be referred to as an orbit or rotation 280.

FIG. 5a is top-view diagram of the horizontal plane illustrating an example a prior art apparatus 50 in which the particle stream 70 is not deflected.

FIG. 5b is a top-view diagram illustrating an example of a particle stream that is deflected in the same direction in which the cathode 212 rotates 280. In other words, the deflection direction 94 of the deflected particle stream 90 is the same as the rotation direction 280. The density of the coating 82 (which can also be referred to as the deposit 82) on the surface 80 can be enhanced.

FIG. 5c is a top-view diagram illustrating an example of a particle stream that is deflected in the direction opposite to the rotation of the cathode 212. In other words, the deflection direction 94 of the deflected particle stream 90 is opposite to the rotation direction 280. A deflected particle stream 90 differs in several respects from a non-deflected particle stream 70. A deflected particle stream 90 increases the porosity of the coating 82 (which can also be referred to as the deposit 82) on the surface 80 being sprayed. Such a particle stream 90 is less collimated, with a wider and non-symmetrical spay pattern. Also, by creating a less collimated spray pattern there is less localized heating of the surface 80. In addition, not all of the particles in the particle stream 90 will adhere to the surface 80, and the particles that do not adhere will be deflected and/or splash off the surface 80. With a deflected particle stream 90 these particles not adhering to the surface 80 are less likely to build up on the face of the nozzle 220. In addition, by performing horizontal deflection 91 as opposed to vertical deflection 92, there will be less buildup of these particles not adhering to the surface on the torch body 202 above the nozzle 220.

VI. ASSEMBLY VIEW

The system 100, which includes the nozzle 220 with a non-symmetrical passageway configuration 249 can be implemented in a variety of different ways using a variety of different assemblies, with each assembly having a variety of different viable operating environments.

A. Component Views

As illustrated in FIG. 6a, the system 100 or a corresponding apparatus 110, can be implemented while including a torch assembly 200, a wire feed assembly 300, a power delivery assembly 400, a gas delivery assembly 500, and in some embodiments, a sensor assembly 600 and an IT assembly 700. The nozzle 220 is a component of the torch assembly 200, although it includes nozzle passageways 240 for the direction of secondary gas 518 to the particle stream 70. As illustrated in the Figure, the non-symmetrical nozzle passageway configuration 249 is an attribute of the torch assembly 200, which includes the nozzle 220.

The illustration of FIG. 6b is similar to that of FIG. 6a, except that the non-symmetrical attributes exist outside the nozzle 220 and within a secondary gas director 570 that is part of the gas assembly.

B. Schematic Views

FIG. 6c is a schematic diagram illustrating an example of the system. FIG. 6d is an enlarged representation of a portion of FIG. 6c.

The apparatus 110 includes a torch assembly 200 containing a plasma gas port 532 and a secondary gas port 534. The torch body 202 is typically formed of an electrically conductive metal. The plasma gas 512 is connected by means of a plasma gas port 532 to a cathode holder 214 through which the plasma gas 512 flows into the inside of the cathode subassembly 210 and exits through gas ports 216 located in the cathode holder 214. The plasma gas 512, which typically forms a vortex flow between the outside of the cathode subassembly 210 and the internal surface of the plasma nozzle 222, and then it exits through the constricting orifice 224. The plasma gas vortex provides substantial cooling of the heat being generated by the functioning of the cathode 212.

Secondary gas 518 enters the torch assembly 200 through secondary gas ports 534 which direct the secondary gas 518 to a gas manifold 550 (a cavity formed between a baffle plate 578 and the torch body 202 and then through bores 556 in the baffle 578. In a symmetrical configuration, the secondary gas 518 flow is uniformly distributed through the equiangularly spaced passageways 540 concentrically surrounding the outside of the constricting orifice 224. In a non-symmetrical passageway configuration 549, the flow of the secondary gas 518 is not uniformly distributed.

Wire feedstock 320 is used supply the plasma arc 60 with the material that is sprayed onto the surface 84. The wire 310 is directed by rollers 340 that are powered by a speed-controlled motor 350. The wire 310 moves through a wire contact tip 422 which is in electrical contact to the wire 310 as it slides through the wire contact tip 422. In this embodiment, the wire contact tip 422 is composed of two pieces, 422A and 422B, held in spring or pressure load contact with the wire 310 by means of one or more rubber rings 432 or other suitable means. The wire contact tip 422 is made of high electrically conducting material. As the wire 310 exits the wire contact tip 422, it enters a wire guide tip 330 for guiding the wire 310 into a desired alignment with the axial centerline 76 of the constricting orifice 224. The wire guide tip 330 can be supported in a wire guide tip block within an insulating block 434 which provides electrical insulation between the torch body 202, which is held at a negative electrical potential, while the wire guide tip block 332 and the wire contact tip 422 are held at a positive potential. In other embodiments, the wire guide tip 330 can be structurally integral with the nozzle 220. A small port 536 in the insulator block 434 allows a small amount of secondary gas 518 to be diverted through the wire guide tip block 332 in order to provide heat removal from the block 332. This can also be done via a bleed gas 510 around or through the nozzle 220. In some embodiments, the wire guide tip block 332 can be maintained in pressure contact with the plasma nozzle 222 to provide an electrical connection between the plasma nozzle 222 and the wire guide tip block 332. Electrical connection is made to the torch body 202 and thereby to the cathode subassembly 210 (which includes the cathode 212) through the cathode holder 214 from the negative terminal of the power supply 410. In some embodiments, the power supply 410 may contain both a pilot power supply and a main power supply operated through isolation contactors. Positive electrical connection can be made to the wire contact tip 422 from the positive terminal of the power supply 410. Wire 310 is fed toward the axial centerline 76 of the constricting orifice 224, which is also the axis of the plasma plume 62. Concurrently, the cathode subassembly 210 is electrically energized with a negative charge and the wire 310, as well as the plasma nozzle 222 although the plasma nozzle 222 can be isolated, it can be electrically charged with a positive charge. The wire guide tip 330 and wire 310 can be positioned relative to the plasma nozzle 222 by many different methods. In one embodiment, the plasma nozzle 222 itself can have features for holding and positioning of the wire guide tip 330. The torch body 202 may be desirably mounted on a power rotating support (not shown) which revolves the torch around the wire axis to coat the interior of bores.

To initiate operation of the apparatus 110, plasma gas 512 at an inlet gas pressure of between 35 and 140 psig is caused to flow through the plasma gas ports 532, typically creating a vortex flow of the plasma gas 512 about the inner surface of the plasma nozzle 222 and then, after an initial period of time of typically two seconds, high-voltage DC power or high frequency power is connected to the electrodes creating the plasma arc 60. Wire 310 is fed by means of wire feed rollers 340 into the plasma arc 60 sustaining it even as the free end 370 is melted off by the intense heat of the plasma arc 60 and its associated plasma 68 which surrounds the plasma arc 60. Molten metal particles can be formed on the free end 370 of the wire 310 which are then atomized into fine, particles 74 by the viscous shear force established between the high velocity, ionized plasma gas 516 and the initially, stationary molten droplets. The molten particles can be further atomized and accelerated by the much larger mass flow of secondary gas 518 through passageway 540 which converge at a location or zone beyond the melting of the wire free end 370, now containing the finely atomized particles 74, which are propelled to the substrate surface 80 to form a deposit 82 on a desired substrate 84.

The wire 310 can be melted with the particles 70 being carried and accelerated by vector forces 66 in the same direction as the plasma arc 60. A uniform dispersion 70 of fine particles 74, without aberrant globules 72, can be obtained. The vector forces 66 are the axial force components of the plasma arc energy and the high level converging secondary gas 518 streams. However, under some conditions, instabilities occur where particles from the melted wire free end 370 are not uniformly melted as the cathode subassembly 210 is rotated around the rotational centerline 206 of the wire 310 whereby some part of the wire free end 370 is accelerated away from the free end 370 in larger droplets 72 which are not atomized into fine particles 74. These large particles or droplets 72 are propelled as large agglomerate masses toward the substrate 84 and are included into the coating (i.e. deposit 82) as it is being formed, resulting in coating of poor quality.

As indicated earlier, high velocity secondary gas 518 is released from typically equi-angularly spaced bores 556 to project a curtain of secondary gas 518 streams about the plasma arc 60. The supply 524 of secondary gas 518, such as air, is introduced into the chamber 550 under high flow, with a pressure of about 20-120 psi. The chamber 550 (i.e. gas manifold 550) acts as a plenum to distribute the secondary gas 518 to the series of typically equi-angularly spaced passageways 540 which direct the secondary gas 518 as a concentric converging stream which assists the atomization and acceleration of the particles 70. Each passageway 540 can have an internal diameter of about 0.040-0.090 inches and projects a high velocity air flow at a flow rate of about 10-60 scfm from the total of all of the passageway 540 combined. The plurality of passageways 540, typically ten in number, are located concentrically around the constricting orifice 224, and are radially and substantially equally spaced apart. To avoid excessive cooling and turbulence in the arc zone at the plasma arc 60, these streams are typically radially located so as not to impinge directly on the wire free end 370. The passageways 540 are spaced angularly apart so that the wire free end 370 is centered midway between two adjacent passageways 540, when viewed along the axial centerline 76 of the constricting orifice 224. Thus, as shown in FIG. 6d, nozzle passageways 240 will not appear because the section plane is through the wire 310. FIG. 6c shows the nozzle passageways 240 only for illustration purposes and it should be understood they are shown out of position (typically 18 degrees for a nozzle 220 with 10 radial nozzle passageways 240) and are not in the section plane for this view. The converging angles of the streams of secondary gas 518 are typically about 30 degrees relative to the center vector 78, permitting the secondary gas 518 to engage the particles 70 downstream of the wire-plasma intersection zone 64.

FIG. 6d is an enlarged representation of a portion of FIG. 6c. FIG. 6d focuses more on the components surrounding the cathode 212 and the nozzle 220, which is a plasma nozzle 222. There are passageways 540 in the gas manifold 550 through which secondary gas 518 is directed towards the particle stream 70. The gas manifold 550 includes a baffle plate 578. Plasma gas 512 enters the figure through a plasma gas port 532. The view also includes an insulating block 434.

A cathode assembly 210 includes the cathode holder 214 which secures the position of the cathode 212. Down from the opening 224 in the nozzle 220 (the plasma nozzle 222) is the wire 310 which moves through the guide tip 330. The free end 370 of the wire 310. The center vector 78 is illustrated as a dotted line bisecting the cathode 212 down to the free end 370 of the wire 310

VII. ALTERNATIVE EMBODIMENTS

The system 100 can be implemented with respect to virtually any prior art apparatus 50. The system 100 can be implemented using a wide variety of different assemblies, components, and component configurations. The system 100 can also be implemented using a variety of different non-symmetrical passageway configurations 549 to deflect the particle stream 70 in a horizontal and/or vertical manner.

No patent application can disclose through text descriptions or graphical illustrations all of the potential embodiments of an invention. In accordance with the provisions of the patent statutes, the principles and modes of operation of the system are explained and illustrated with respect to certain preferred embodiments. However, it must be understood that the components, configurations, and methods described above and below may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. Each of the various components, assemblies, and other elements described in the glossary set forth in Table 1 above can be implemented in a variety of different ways while still being part of the spirit and scope of the invention.

Number	Name	Date	Kind
5269462	Suzon	Dec 1993	A
5908670	Dunkerley	Jun 1999	A
8581138	Kowalsky	Nov 2013	B2
20020185473	Carlson	Dec 2002	A1
20050223977	Vardelle	Oct 2005	A1
20100151124	Xue	Jun 2010	A1

System, apparatus, and method for deflected thermal spraying

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