Wire combustion with increased application rates

Abstract

Shaping the feed wire for a combustion wire thermal spray process improves the operating capability of the combustion wire gun through higher feed rates and high operating efficiencies. The efficiency of the wire melting is increased over conventional systems through increasing the surface area of the wire cross section and exposing more of the wire material directly to the burner jets.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:

FIG. 1 provides a schematic of a conventional combustion wire spray gun for use in accordance with the present invention;

FIG. 2A provides a conventional feed wire cross section;

FIG. 2B provides a cross-section of a feed wire in accordance with an embodiment of the present invention;

FIG. 3 provides an isometric comparison of a conventional feed wire and a feed wire in accordance with the present invention;

FIG. 4 provides a comparison of actual coatings produced with conventional round wire and with lobed shaped wire in accordance with an embodiment of the present invention;

FIG. 5 provides a cross-shaped cross section of a feed wire in accordance with an embodiment of the present invention;

FIG. 6 provides a star-shaped cross section of a feed wire in accordance with an embodiment of the present invention;

FIG. 7 provides a flattened oval or ribbon cross section of a feed wire in accordance with an embodiment of the present invention;

FIG. 8 provides a three-legged cross section of a feed wire in accordance with an embodiment of the present invention; and

FIG. 9 provides a six-legged cross section of a feed wire in accordance with an embodiment of the present invention.

Claims

1. A combustion wire thermal spray system, comprising: a wire feed system;a wire feedstock wherein said wire feedstock has a cross-section, said cross-section having a perimeter greater than

2. The system of claim 1, wherein the wire cross-section perimeter is substantially concentric.

3. The system of claim 1, wherein the wire cross-section perimeter is at least 1.3 times that of a circle with equal interior area.

4. The system of claim 1, wherein the cross-section is one of a substantially cross shape with three or more legs, a substantially star shape with three or more points, a substantially gear shape with three or more lobes, substantially an oval, or substantially a ribbon.

5. The system of claim 1, wherein the wire feedstock is formed using drawing, extruding, or forming techniques.

6. The system of claim 1, wherein the wire feedstock is preheated prior to being fed into the combustion chamber.

7. A method of generating combustion wire thermal spray, comprising: providing a wire with a cross-section that has a perimeter greater than

8. The method of claim 7, wherein the wire perimeter is substantially concentric.

9. The method of claim 7, wherein the wire perimeter is at least 1.3 times that of a circle with equal interior area.

10. The method of claim 7, wherein the cross-section is one of a substantially cross shape with three or more legs, a substantially star shape with three or more points, a substantially gear shape with three or more lobes, substantially an oval, or substantially a ribbon.

11. The method of claim 7, wherein the wire feedstock is formed using drawing, extruding, or forming techniques.

12. The method of claim 7, wherein the wire feedstock is preheated prior to being fed into the combustion wire gun.