Not applicable.
Not applicable.
Not applicable.
With the advent of plasma guns having wide operating ranges through the use of different plasma forming nozzles (see, e.g., ITSC 2005 technical paper on plasma forming nozzles for Triplex), the ability of a plasma gun to produce a wide array of thermal spray coatings became possible. One example is the application of thermal barriers where two coating layers are required. In such barrier coatings, the first layer is a bonding layer typically comprised of an MCrAlY type superalloy material that is applied at high particle velocities and relatively low particle temperatures. The second coating is a ceramic thermal barrier applied at low particle velocities and high particle temperatures. In applying such coatings, two different plasma nozzles are utilized. One nozzle is a high enthalpy straight bore nozzle. The other is a high velocity laval type nozzle.
In order to produce such a complete coating system, either two separate guns are required or two spray cells must be utilized, or, at best, the gun hardware needs to be manually changed—which requires interrupting the coating process. In fact, current systems require manual disassembly of at least part of the gun to change the hardware, and more specifically the nozzle, in order to change the operating regime of the gun. Also known in the art is the ability to automatically change entire guns with each gun configured with the appropriate gun hardware for the required operating regime. This method entails considerable additional hardware and capital expense for switching the high energy and gas utility feeds to the “active” gun.
What is needed is a thermo spray gun with interchangeable nozzle tips and/or a method for automatically changing plasma gun nozzles (or nozzle tips) to facilitate changing the operating regime of the gun to suit the various applications for multi-layer coating systems.
In accordance with one non-limiting embodiment, there is provided a thermo spray gun or system which overcome one or more of the disadvantages of conventional systems.
In accordance with one non-limiting embodiment, there is provided a thermo spray gun comprising at least one of: at least one removable nozzle tip for spraying a coating material, at least one replaceable nozzle tip for spraying a coating material, and at least one interchangeable nozzle tip for spraying a coating material.
In embodiments, the nozzle tip is mechanically coupled to an anode section of the thermo spray gun.
In embodiments, the nozzle tip is electrically coupled to an anode section of the thermo spray gun.
In embodiments, the nozzle tip is removable from the thermo spray gun while an anode section remains coupled to the thermo spray gun.
In embodiments, the nozzle tip is removable from the thermo spray gun with an anode section.
In embodiments, the nozzle tip includes an anode section of the thermo spray gun.
In embodiments, the thermal spray gun is one of a plasma spray gun and a HVOF spray gun.
In embodiments, the thermo spray gun further comprises at least one feedstock supply line coupled to a portion of the thermo spray gun.
In embodiments, the thermo spray gun further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot.
In embodiments, the thermo spray gun is utilized in combination with a station or location storing a plurality of nozzle tips.
In embodiments, the thermal spray gun is utilized in combination with a station or location storing a plurality of different nozzle tips.
In embodiments, the thermal spray gun is utilized in combination with a station or location storing a plurality of nozzle tips arranged at a predetermined location that is different from a location containing a substrate being sprayed with the coating material.
In accordance with one non-limiting embodiment, there is provided a thermo spray gun system comprising a thermal spray gun and at least one mechanism at least one of; storing at least one nozzle tip installable on the thermal spray gun and being structured and arranged to install at least one nozzle tip on the thermal spray gun.
In embodiments, the system further comprises a control controlling at least one of; movement of the thermal spray gun and installation of the at least one nozzle tip installable on the thermal spray gun.
In embodiments, the at least one nozzle tip is at least one of; at least one removable nozzle tip for spraying a coating material, at least one replaceable nozzle tip for spraying a coating material, and at least one interchangeable nozzle tip for spraying a coating material.
In embodiments, the system further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot.
In embodiments, the system is utilized in combination with a station or location storing the at least one mechanism.
In embodiments, the system further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot and a control controlling at least one of; movement of the thermal spray gun and installation of the at least one nozzle tip installable on the thermal spray gun.
In embodiments, the system further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot and a control controlling at least one of; programmed movement of the thermal spray gun and programmed or automatic installation of the at least one nozzle tip installable on the thermal spray gun.
In embodiments, the system further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot and a control controlling movement of the thermal spray gun and installation of the at least one interchangeable nozzle tip on the thermal spray gun.
In accordance with one non-limiting embodiment, there is provided a thermo spray gun system comprising a thermal spray gun and at least one mechanism comprising at least first and second nozzle tips and being movable between; a first position wherein the first nozzle nip is utilized to spray a coating material and a second position wherein the second nozzle nip is utilized to spray a coating material.
In embodiments, the system further comprises a control controlling at least one of; movement of the thermal spray gun and movement of the at least one mechanism between the first and second positions.
In embodiments, the system further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot.
In embodiments, the system is utilized in combination with a station or location storing the at least one mechanism.
In embodiments, the system is utilized in combination with a station or location storing a plurality of the at least one mechanism.
In embodiments, the system further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot and a control controlling movement of the at least one mechanism between the first and second positions.
In embodiments, the system further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot and a control controlling at least one of, programmed movement of the thermal spray gun and programmed movement of the at least one mechanism between the first and second positions.
In embodiments, the system further comprises a robot, wherein the thermo spray gun is mounted to an arm of the robot and a control controlling movement of the thermal spray gun and movement of the at least one mechanism between the first and second positions.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises mounting at least one nozzle tip on the thermo spray gun and spraying a coating material with the at least one nozzle tip.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises removably mounting at least one nozzle tip on the thermo spray gun and spraying a coating material with the at least one nozzle tip.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises mounting at least one nozzle tip on the thermo spray gun, spraying a coating material with the at least one nozzle tip, removing the at least one nozzle tip from the thermal spray gun, and mounting another at least one nozzle tip on the thermo spray gun.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises moving the thermo spray gun to a predetermined location and mounting at least one nozzle tip on the thermo spray gun.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises spraying a coating material with the at least one nozzle tip, moving the thermo spray gun to a predetermined location, and removing the at least one nozzle tip from the thermal spray gun.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises automatically moving the thermo spray gun to a predetermined location and automatically removing the at least one nozzle tip from the thermal spray gun.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises automatically moving the thermo spray gun to a predetermined location and automatically installing at least one nozzle tip onto the thermal spray gun.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises automatically moving the thermo spray gun to a predetermined location, automatically removing the at least one nozzle tip onto the thermal spray gun, and automatically installing another at least one nozzle tip onto the thermal spray gun.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises spraying a coating material with the at least one nozzle tip, moving the thermo spray gun to a predetermined location, removing the at least one nozzle tip onto the thermal spray gun, installing an other at least one nozzle tip onto the thermal spray gun, and spraying a coating material with the other at least one nozzle tip.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises spraying in a controlled manner a coating material with the at least one nozzle tip, moving in a controlled manner the thermo spray gun to a predetermined location, removing in a controlled manner the at least one nozzle tip onto the thermal spray gun, installing in a controlled manner an other at least one nozzle tip onto the thermal spray gun, and spraying in a controlled manner a coating material with the other at least one nozzle tip.
In accordance with one non-limiting embodiment, there is provided a method of coating a substrate using a thermo spray gun, wherein the method comprises spraying a coating material with the at least one nozzle tip, automatically moving the thermo spray gun to a predetermined location, automatically removing the at least one nozzle tip onto the thermal spray gun, automatically installing an other at least one nozzle tip onto the thermal spray gun, and spraying a coating material with the other at least one nozzle tip.
Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawings.
The present invention is further described in the detailed description which follows, in reference to the noted drawings by way of a non-limiting example embodiment of the present invention, and wherein:
The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.
In accordance with one non-limiting embodiment of the invention, there is provided a thermo spray gun 10 which includes at least one of: at least one removable nozzle tip 4 for spraying a coating material, at least one replaceable nozzle tip 4 for spraying a coating material, and at least one interchangeable nozzle tip 4 for spraying a coating material.
In accordance with another non-limiting embodiment, there is provided a thermo spray gun system 1000 comprising a thermal spray gun 10 and at least one mechanism 30 comprising at least first and second nozzle tips 20 and being movable between a first position wherein the first nozzle nip is utilized to spray a coating material and a second position wherein the second nozzle nip is utilized to spray a coating material.
In accordance with still another non-limiting embodiment, there is provided a thermo spray gun system 1000 comprising a thermal spray gun 10 and at least one mechanism, e.g., support 30 and/or fixture 40, at least one of storing at least one nozzle tip 20 installable on the thermal spray gun 10 and being structured and arranged to install at least one nozzle tip 20 on the thermal spray gun 10. Such a system is preferably an automated system.
With an automated interchangeable nozzle system 2000, the processing of complex coating systems with different layered materials can be undertaken in one process step or station 30 without the need for manual hardware changes and the lost production time associated with manual intervention. In addition the time between layer applications is reduced and this can lead to improved adhesion between the layers and overall coating quality.
With reference to
The embodiment of
To facilitate easy or automatic removal or installation of the nozzle tip 4, an exposed outer section or diameter 9 of the nozzle insert or tip 4 is configured to be gripped. In embodiments, this section 9 can optionally have a groove (not shown) into which a gripping device, e.g., a collet or chuck type gripping device, can grip or grab the nozzle insert 4. The collet or chuck can preferably be driven by a spindle or motor so that it can rotate the gripped nozzle tip 4. For example, the gripping device can grip the section 9 of the tip 4 and rotate it in one direction so as to unscrew it (and remove it) from the plasma gun 10 and rotate it in an opposite direction to screw the nozzle tip 4 into the nozzle base 3 (and installed the same). When the gripping device is used in an automated context, the gripping device (gripping section 9) and plasma gun 10 have their movements coordinated so that one nozzle tip 4 is removed from the plasma gun 10 and another is installed on the plasma gun 10 in a controlled or pre-programmed way. In embodiments, the gripping device can utilize a spring (not shown) loaded in the axial direction and that can apply a force against the face of the gun. The spring would function to allow the collet to move axially as a nozzle tip 4 is threaded on or off the plasma gun 10.
The embodiments of
With reference to
With reference to
With reference to
An exemplary way of utilizing the arrangement 2000 in
An exemplary fixture 40 as described can preferably handle, store or retain thereon almost any number of nozzle tips 20 (whether different or not) as is required for a specific job or process. The fixture 40 can also include as many different nozzle tips 20 as are available for the specific plasma gun.
With reference to
Although the embodiment of
With reference to
With reference to
With reference to
With reference to
It is noted that the materials and sizes for the nozzle tips can be similar to that used in known plasma guns which does not utilize interchangeable/removable nozzle tips.
It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and sprit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US2012/022906 | 1/27/2012 | WO | 00 | 5/30/2014 |