Abstract:
An improved thermal spray apparatus and method of promotes mixing of axially fed particles in a carrier stream with a heated effluent stream without introducing significant turbulence into either the effluent or carrier streams. An axial injection port includes a plurality of chevrons at the distal end of the port. The chevrons are located radially around the circumference of the distal end of the axial injection port to increase the shared area between the two flow streams at the outlet of the port.
Abstract:
Methods for combining conductive filled low surface energy substrates, such as but not limited to polyolefins, and flame applied nitrogen based coupling agents are described. The methods include adding a conductive material to a surface and or matrix of the thermoplastic substrate so as to form a conductive thermoplastic substrate and a flame applied nitrogen-based coupling agent to form functional groups on the conductive thermoplastic substrate. The methods provide improved paint transfer efficiency, paint coverage, and adhesion durability characteristics. The methods are especially suitable for paintable automotive components, such as but not limited to exterior body panels, fascias, and the like.
Abstract:
Coatings, particularly thin films, of polymeric material are produced in accordance with the invention by applying a finely divided aerosol of polymer solution to a substrate and substantially simultaneously applying an energy source to the applied solution to apply the solution. In cases where the polymer is cross-linking, the energy source assists in cross-linking of the polymer. The preferred energy source is a flame that may optionally or desirably deposit material along with the polymer spray. One particular aspect of the invention is directed to production of polyimide films. In accordance with another aspect of the invention, the co-deposition process is used to provide thin polysiloxane coatings on glass and other substrates.
Abstract:
A method for repairing minor defects in a workpiece using flame spraying is provided. The method includes first providing a workpiece having a defect and an area proximate to the defect. The method also includes routing a portion of the workpiece, including the defect, such that the routing removes at least a portion of the workpiece proximate to the defect. The depth to which the workpiece is routed may be controlled with a micro-stop countersink apparatus. A router bit is generally plunged into the workpiece in a direction orthogonal to the surface of the workpiece such that the routed portion of the workpiece defines a sidewall extending generally orthogonal to the workpiece and a conical bottom surface. The portion of the workpiece that has been removed by routing is then flame sprayed such that new material is added to fill the portion of the workpiece that has been routed.
Abstract:
A primer for flame sprayed polyolefin comprises an epoxy resin, preferably of low molecular weight and/or low viscosity; and an amine hardener, part of which becomes highly reactive on exposure to open flame, providing near instant cure of the composition under flame spray conditions. The invention is unique that it provides strong adhesion to steel, even where the surface preparation is less than ideal, as well as to concrete and other substrates. The primer eliminates the need to preheat the substrate. The primer has strong adhesion to the topcoat polyolefinic material, especially to a functionalized topcoat. The composition withstands open flame and does not char under polyolefin flame spray conditions, nor does it run or sag, and it is not prone to failure as it cools after the application of the polyolefin.
Abstract:
A coherent material is formed on a substrate (10) by providing a precursor suspension (14) in which particulates are suspended in a carrier fluid, and directing the precursor suspension (14) at the substrate (10) from a first source (12). Generally contemporaneously with application of the deposited precursor suspension (14) to the surface, hot gases, e.g. hot gases produced by a flame (16), are directed at the substrate (10) from a remote second source (18) to fuse the particulates into the coherent material.
Abstract:
A method for chemical vapor deposition using a very fine atomization or vaporization of a reagent containing liquid or liquid-like fluid near its supercritical temperature, where the resulting atomized or vaporized solution is entered into a flame or a plasma torch, and a powder is formed or a coating is deposited onto a substrate. The combustion flame can be stable from 10 torr to multiple atmospheres, and provides the energetic environment in which the reagent contained within the fluid can be reacted to form the desired powder or coating material on a substrate. The plasma torch likewise produces the required energy environment, but, unlike the flame, no oxidizer is needed so materials stable in only very low oxygen partial pressures can be formed. Using either the plasma torch or the combustion plasma, coatings can be deposited and powders formed in the open atmosphere without the necessity of a reaction chamber, but a chamber may be used for various reasons including process separation from the environment and pressure regulation.
Abstract:
A method of manufacturing a metal and polymeric composite article by the following steps. Droplets of spray deposited metal and spray deposited polymeric material are combined to form an article having the polymeric material interspersed within the metal. A carrier or form that shaped to receive the metal and polymeric layers is provided. The carrier may be made either stationary or movable. Layers of spray deposited metal and spray deposited polymeric material are applied atop the carrier. The spray deposited metal is between 90 and 95 percent by volume of the article. The polymeric layers do not completely cover the metal layers. Succeeding spray deposited metal layers contact bond to previous metal layers. The polymeric material between imbedded between the interconnected metal layers.
Abstract:
A method for chemical vapor deposition using a very fine atomization or vaporization of a reagent containing liquid or liquid-like fluid near its supercritical temperature, where the resulting atomized or vaporized solution is entered into a flame or a plasma torch, and a powder is formed or a coating is deposited onto a substrate. The combustion flame can be stable from 10 torr to multiple atmospheres, and provides the energetic environment in which the reagent contained within the fluid can be reacted to form the desired powder or coating material on a substrate. The plasma torch likewise produces the required energy environment, but, unlike the flame, no oxidizer is needed so materials stable in only very low oxygen partial pressures can be formed. Using either the plasma torch or the combustion plasma, coatings can be deposited and powders formed in the open atmosphere without the necessity of a reaction chamber, but a chamber may be used for various reasons including process separation from the environment and pressure regulation.
Abstract:
A process for forming metal bars with a non-skid coat by arranging a plurality of the bars in a side-by-side assembly and thermally applying a metallic spray coat simultaneously to a plurality of the bars while inhibiting bridging of the spray material across adjacent bars.