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A supersonic flame spray apparatus capable of forming a high-energy stream of a particulate feedstock for flame spray applications. The flame spray apparatus includes a converging throat in which a two-stage exothermic reaction is created and maintained comprising a flame front and a steady-state co

A supersonic flame spray apparatus capable of forming a high-energy stream of a particulate feedstock for flame spray applications. The flame spray apparatus includes a converging throat in which a two-stage exothermic reaction is created and maintained comprising a flame front and a steady-state continuous detonation. As fuel gas is injected into the flame front, a steady-state continuous detonation reaction is achieved in a fuel-rich zone. A partriculate feedstock is fed into the converging throat at a low-pressure region of the continuous detonation and then passes through the flame front heating the particles. The heated particles are entrained in the expanding combustion gases which flow in an axial high-velocity collimated particle spray stream through a tubular barrel. In one aspect, the flame spray apparatus includes a two-wire arc assembly positioned spatially along the axial center line of the particle stream exiting the barrel. The wires are melted by an electric arc in an arc zone and the molten metal is atomized by the collimated particle stream emerging from the barrel outlet to form a composite particle stream which contains two dissimilar feedstocks. Spray-formed materials are also provided including substantially fully dense metal-matrix composites which may be formed as coatings or as freestanding near-net shapes.

대표청구항 ▼

A supersonic thermal spray apparatus, comprising: a powder thermal spray apparatus including a body portion having an inlet receiving powdered feedstock and a carrier gas, means heating said powdered feedstock and accelerating said heated powdered feedstock and carrier gas, and a nozzle having an in

A supersonic thermal spray apparatus, comprising: a powder thermal spray apparatus including a body portion having an inlet receiving powdered feedstock and a carrier gas, means heating said powdered feedstock and accelerating said heated powdered feedstock and carrier gas, and a nozzle having an inlet receiving said heated powdered feedstock and carrier gas and an outlet directing said heated powdered feedstock toward a target, said carrier gas being accelerated to supersonic velocity; and feed means feeding a molten metal feedstock into said heated powdered feedstock adjacent said nozzle outlet, said powdered feedstock and carrier gas atomizing said molten metal feedstock and projecting said atomized molten metal feedstock substantially uniformly distributed in said heated powdered feedstock toward said target.