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1. 发明授权

US5820939A Method of thermally spraying metallic coatings using flux cored wire 失效
标题翻译：使用药芯焊丝热喷镀金属涂层的方法
公开(公告)号：US5820939A
公开(公告)日：1998-10-13
申请号：US829666
申请日：1997-03-31
申请人： Oludele Olusegun Popoola , Matthew John Zaluzec , Armando Mateo Joaquin , Deborah Rose Pank , David James Cook
发明人： Oludele Olusegun Popoola , Matthew John Zaluzec , Armando Mateo Joaquin , Deborah Rose Pank , David James Cook
IPC分类号： C23C4/02 , B05B7/22 , B05B13/06 , C23C4/04 , C23C4/16 , C23C4/06
CPC分类号： C23C4/04 , B05B13/0636 , B05B7/224
摘要： A method of thermally spraying at least one adherent metallic coating onto an unroughened cleansed aluminum or aluminum alloy substrate to produce a coated substrate, comprising: wire-arc thermally spraying of melted metallic bonding droplets and fluxing particles onto the substrate using air propulsion to concurrently adherently deposit flux particles and bonding droplets, the spraying using air propulsion and a wire feedstock having a core and a sheath, the wire core being constituted of both metal powder readily metallurgically bondable to the substrate and a fluxing powder that readily deoxidizes the substrate, the wire sheath being constituted of pliable metal that is metallurgically compatible with the core metal powder, the fluxing powder having a halide salt chemistry effective to deoxidize the substrate upon contact of the melted fluxing powder therewith, said fluxing powder and bonding metal having a particle size that more uniformly promotes distribution throughout said spray. A flux cored wire for use in thermal spraying of aluminum or aluminum alloy substrates, comprising (a) a powder core mixture consisting of (i) a metal bonding powder effective to metallurgically bond by an exothermic reaction with the substrate when the bonding metal powder is in a melted condition, (ii) a fluxing powder effective to strip aluminum oxides from said substrates when in the melted condition, (b) a pliable metal sheath encapsulating the powder mixture and having a composition that is metallurgically compatible with the bonding metal and also is effective to react with aluminum surfaces to form intermetallics.
摘要翻译：一种将至少一种粘附金属涂层热喷涂到未增韧的清洁的铝或铝合金基底上以产生涂覆的基底的方法，其包括：使用空气推进线将弧熔融的金属粘结液滴和助熔颗粒热喷涂到基底上以同时粘附沉积助焊剂颗粒和结合液滴，使用空气推进的喷涂和具有芯和护套的焊丝原料，所述焊丝芯由易于冶金地结合到衬底的金属粉末和易于使衬底脱氧的助熔粉末构成，所述焊丝护套由与金属粉末冶金相容的柔韧金属构成，该助熔粉末具有卤化物盐化学物质，其有效地使熔融的助熔粉末与其接触时使基底脱氧，所述助熔粉末和结合金属具有更大的粒径均匀地促进分布在整个spra y。一种用于铝或铝合金基底的热喷涂的药芯焊丝，包括（a）粉末芯混合物，其包含（i）当所述粘合金属粉末为接合金属粉末时，通过放热反应与所述基板有效地冶金结合的金属粘合粉末在熔融状态下，（ⅱ）当处于熔融状态时，有效地从所述基底上剥离氧化铝的助熔粉末，（b）包裹粉末混合物并具有与粘合金属冶金学相容的组成的柔韧金属鞘，以及有效地与铝表面反应形成金属间化合物。

2. 发明授权

US5820938A Coating parent bore metal of engine blocks 失效
标题翻译：涂覆发动机缸体的母孔金属
公开(公告)号：US5820938A
公开(公告)日：1998-10-13
申请号：US829395
申请日：1997-03-31
申请人： Deborah Rose Pank , Matthew John Zaluzec , Oludele Olusegun Popoola , Robert Edward DeJack , James R. Baughman , David James Cook
发明人： Deborah Rose Pank , Matthew John Zaluzec , Oludele Olusegun Popoola , Robert Edward DeJack , James R. Baughman , David James Cook
IPC分类号： F02F1/00 , B05D1/04 , B23K1/20 , B23K9/04 , C23C2/02 , C23C4/02 , C23C4/12 , B05D1/09
CPC分类号： C23C2/02
摘要： A method of fluxing a cast light-weight metal substrate for thermally adhering sprayed metallic coatings thereto, comprising: (a) preparing the substrate to be clean of grease and oil and to have a uniform and homogeneous surface energy; (b) electrostatically depositing a dry flux powder coating onto such prepared surface; and (c) thermally depositing melted metal onto and across the flux coated surface to further thermally activate the flux if not already activated, for stripping away any substrate oxides and to thermally metallurgically bond the deposited molten metal to the substrate.
摘要翻译：一种用于将喷射的金属涂层热粘合的铸造轻量金属基材的方法，包括：（a）制备待清洁的油脂和油的基材，并具有均匀且均匀的表面能; （b）将干燥焊剂粉末涂料静电沉积在这样制备的表面上; 和（c）将融化的金属热沉积到焊剂涂覆的表面上并穿过焊剂涂覆的表面，以进一步热激活焊剂，如果没有被激活，则剥离任何衬底氧化物，并将沉积的熔融金属热冶金结合到衬底。

3. 发明授权

US5922412A Method of eliminating unevenness in pass-reversal thermal spraying 失效
标题翻译：消除反向热喷涂不均匀的方法
公开(公告)号：US5922412A
公开(公告)日：1999-07-13
申请号：US48267
申请日：1998-03-26
申请人： James Richard Baughman , David James Cook
发明人： James Richard Baughman , David James Cook
IPC分类号： C23C4/12
CPC分类号： C23C4/12 , B05B7/224 , B05B13/0636
摘要： A method of eliminating unevenness in pass-reversal thermal spraying of a substrate surface by: uniformly thermally spraying a substrate surface by moving a wire fed arc spray gun along the length of the substrate surface at constant spray parameters while using a first wire feed rate and a first current level for the gun's power supply; (b) when said spray gun approaches an end zone of the pass length requiring reversal of spray gun movement, reducing the wire feed rate and current by up to about 25% until the spray gun has completed such reversal and has exited from said end zone in the opposite direction; (c) while still continuing thermal spraying, restoring the wire feed rage and current to said first levels; and (d) repeating steps (b) and (c) as the spray gun approaches other or repeated end zones of the substrate length during repeated passes.
摘要翻译：一种通过以下步骤消除基板表面的通过反向热喷涂的不均匀性的方法：通过以恒定的喷射参数沿着基板表面的长度移动送丝电弧喷枪来均匀地热喷涂基板表面，同时使用第一焊丝进给速率，枪支电源的第一级; （b）当所述喷枪接近需要反转喷枪运动的通过长度的端部区域时，将送丝速度和电流降低高达约25％，直到喷枪完成这种反转并且已经从所述端部区域退出在相反的方向; （c）在仍然继续热喷涂的同时，将焊丝进给量恢复到第一级; 和（d）重复步骤（b）和（c），因为喷枪在重复通过期间接近基片长度的其他或重复的端部区域。

4. 发明授权

US06372298B1 High deposition rate thermal spray using plasma transferred wire arc 有权
标题翻译：使用等离子体转移线弧的高沉积速率热喷涂
公开(公告)号：US06372298B1
公开(公告)日：2002-04-16
申请号：US09621471
申请日：2000-07-21
申请人： Daniel Richard Marantz , Keith Alan Kowalsky , David James Cook , Larry Gerald Gargol
发明人： Daniel Richard Marantz , Keith Alan Kowalsky , David James Cook , Larry Gerald Gargol
IPC分类号： H05H142
CPC分类号： B05B7/224 , C23C4/131 , C23C4/134
摘要： Method of thermally depositing metal at increased rates onto a target surface, comprising: establishing and operating a high velocity plasma transferred wire arc between a cathode and the free-end of a consumable wire electrode, the energy of such plasma and arc being sufficient to not only melt and atomize the free-end of the wire into metal particles, but also project the particles as a column onto the target surface at an enhanced deposition rate for continuous periods in excess of 50 hours; surrounding the plasma and arc with high velocity and high flow gas streams that converge beyond the intersection of the wire free-end with the plasma-arc to limit turbulence of the plasma-arc, avoid direct impingement with the wire and assist the projection of the particles to the target surface; and impinging a low velocity gas flow along the axis of the advancing wire to counteract any destabilizing fluid dynamic forces attempting to move melted particles back along the wire away from the wire free end.
摘要翻译：将金属以增加的速率热沉积到目标表面上的方法，包括：在阴极和可消耗线电极的自由端之间建立和操作高速等离子体转移线弧，所述等离子体和电弧的能量足以不只将熔丝的自由端熔化和雾化成金属颗粒，而且还以增加的沉积速率将颗粒作为柱投射到目标表面上，持续时间超过50小时; 围绕等离子体和电弧，其高速和高流量气流会聚到超过等离子弧电弧自由端的交点，以限制等离子体电弧的湍流，避免与电线直接碰撞，并协助投影颗粒到目标表面; 并且沿着前进的线的轴线撞击低速气流，以抵抗试图将熔化的颗粒沿着导线远离无电线端移动的任何不稳定的流体动力。

5. 发明授权

US5958520A Method of staggering reversal of thermal spray inside a cylinder bore 失效
标题翻译：在气缸孔内旋转热喷涂的方法
公开(公告)号：US5958520A
公开(公告)日：1999-09-28
申请号：US114120
申请日：1998-07-13
申请人： David James Cook , James Richard Baughman
发明人： David James Cook , James Richard Baughman
IPC分类号： C23C4/12 , C23C4/16
CPC分类号： C23C4/12 , Y10T29/49272
摘要： A method of staggering reversal of thermal spray inside a cylinder bore of an internal combustion engine. The method includes the steps of thermally spraying a surface of the cylinder bore by moving a thermal spray gun along a length of the surface. The method also includes the steps of reversing a direction of travel of the thermal spray gun inside the cylinder bore at different points along the length of the surface to provide a multi-layered coating on the surface.
摘要翻译：一种在内燃机的气缸孔内交错散热的方法。该方法包括通过沿表面的长度移动热喷枪来热喷涂气缸孔的表面的步骤。该方法还包括以下步骤：沿着表面的长度在不同的点处使热喷枪在气缸孔内的行进方向反转，以在表面上提供多层涂层。

6. 发明授权

US5938944A Plasma transferred wire arc thermal spray apparatus and method 失效
标题翻译：等离子转移线电弧热喷涂装置及方法
公开(公告)号：US5938944A
公开(公告)日：1999-08-17
申请号：US61841
申请日：1998-04-09
申请人： James Richard Baughman , David James Cook , Daniel R. Marantz , Keith A. Kowalsky
发明人： James Richard Baughman , David James Cook , Daniel R. Marantz , Keith A. Kowalsky
IPC分类号： B05D7/22 , B05B7/18 , B05B7/22 , B05B13/06 , B23K10/02 , C23C4/12 , B23K10/00
CPC分类号： B23K10/027 , B05B13/0636 , B05B7/224
摘要： A plasma transferred wire arc thermal spray apparatus and method producing an extended-arc and supersonic plasma jet stream for applying a dense metallic coating on a substrate, such as a concave internal surface of a bore. The apparatus includes a plasma generating torch assembling having a cathode and an anode nozzle surrounding the cathode and a wire feeder which continuously feeds the tip of a wire feedstock opposite a constricted nozzle orifice and wherein the wire feedstock is maintained at the same positive electrical potential as the nozzle. Plasma gas is directed into the nozzle, preferably generating a vortex flow around the cathode and exiting the restricted nozzle orifice. The improved apparatus includes a pilot power supply and a high voltage or high frequency power supply which initiates the electric arc and the constricted plasma arc and a separate main power supply which extends the constricted plasma arc to the wire tip. In the disclosed bore coating apparatus and method, the plasma torch assembly is rotated about the longitudinal axis of the wire feedstock while maintaining the electrical connection between the wire feedstock and the nozzle. The apparatus further includes an annular conical port surrounding the restricted nozzle orifice connected to a second gas source which generates an annular conical gas stream surrounding the wire tip having a point of intersection spaced downstream of the wire tip and the second gas is further directed to the wire feed guide to cool the assembly.
摘要翻译：一种等离子体转移的线弧热喷涂装置和方法，其产生用于在诸如孔的凹内表面的基底上施加致密金属涂层的延伸电弧和超音速等离子体射流。该装置包括具有阴极和围绕阴极的阳极喷嘴的等离子体发生火炬装配，以及连线进料器，其将线材原料的尖端连续地供给到与缩小的喷嘴孔口相对的位置，并且其中所述焊丝原料保持在与喷嘴。等离子体气体被引导到喷嘴中，优选地产生围绕阴极的涡流并离开限制的喷嘴孔口。改进的装置包括引导电源和启动电弧和收缩的等离子体电弧的高压或高频电源以及将收缩的等离子体电弧延伸到电线尖端的单独的主电源。在所公开的孔涂装置和方法中，等离子体焰炬组件绕线材原料的纵向轴线旋转，同时保持线材原料和喷嘴之间的电连接。该装置还包括围绕限制喷嘴孔的环形圆锥形端口，其连接到第二气体源，该第二气体源产生围绕线尖的环形锥形气流，其具有在线尖端下游的交点，并且第二气体进一步被引导到送丝导板冷却组件。

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