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Disclosed is a system and a method for applying both a kinetic spray applied coating layer and a thermal spray applied layer onto a substrate using a single application nozzle. The system includes a higher heat capacity gas heater to permit oscillation between a kinetic spray mode wherein the partic

Disclosed is a system and a method for applying both a kinetic spray applied coating layer and a thermal spray applied layer onto a substrate using a single application nozzle. The system includes a higher heat capacity gas heater to permit oscillation between a kinetic spray mode wherein the particles being applied are not thermally softened and a thermal spray mode wherein the particles being applied are thermally softened prior to application. The system increases the versatility of the spray nozzle and addresses several problems inherent in kinetic spray applied coatings.

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1. A method of coating a substrate comprising the steps of: a) providing particles of a material to be sprayed; b) providing a supersonic nozzle having a throat located between a converging region and a diverging region, directing a flow of a gas through the nozzle, and injecting the particles

1. A method of coating a substrate comprising the steps of: a) providing particles of a material to be sprayed; b) providing a supersonic nozzle having a throat located between a converging region and a diverging region, directing a flow of a gas through the nozzle, and injecting the particles into the nozzle and entraining the particles in the flow of the gas; c) maintaining the gas at a temperature insufficient to heat the particles to a temperature at or above their melting temperature in the nozzle and accelerating the particles to a velocity sufficient to result in adherence of the particles on a substrate positioned opposite the nozzle; and d) maintaining the gas at a temperature sufficiently high to heat the particles to a temperature at or above their melting temperature in the nozzle thereby melting the particles and entraining the molten particles in the flow of the gas and directing the entrained molten particles at a substrate positioned opposite the nozzle. 2. The method of claim 1, wherein step a) comprises providing particles having an average nominal diameter of from 50 to 250 microns.3. The method of claim 1, wherein step a) comprises providing particles having an average nominal diameter of from 106 to 250 microns.4. The method of claim 1, wherein step a) comprises providing at least two different types of particles differing in at least one of size or material composition.5. The method of claim 1, wherein step b) comprises providing air, argon, nitrogen, or helium as the gas.6. The method of claim 1, wherein step c) comprises providing the gas at a temperature of from 300 degrees Celsius to a temperature that is seven fold above the melting temperature of the particles.7. The method of claim 1, wherein step b) comprises injecting the particles into the converging region of the nozzle prior to the throat.8. The method of claim 1, wherein step b) comprises injecting the particles directly into the diverging region of the nozzle after the throat.9. The method of claim 1, wherein step b) comprises injecting a plurality of different types of particles differing in at least one of size or material composition directly into the diverging region each at a different location.10. The method of claim 1, wherein step c) comprises accelerating the particles to a velocity of from 300 to 1500 meters per second.11. The method of claim 1, wherein step d) comprises heating the particles to a temperature of from their melting temperature to a temperature 400 degrees Celsius above their melting temperature.12. The method of claim 1, wherein step d) comprises heating the particles to a temperature of from their melting temperature to a temperature 200 degrees Celsius above their melting temperature.13. The method of claim 1, wherein step d) comprises heating the particles to a temperature of from their melting temperature to a temperature 100 degrees Celsius above their melting temperature.14. The method of claim 1, wherein step c) is carried out prior to step d) to produce a laminate on the substrate of a kinetic spray applied layer and a thermal spray applied layer.15. The method of claim 1, wherein step d) is carried out prior to step c) to produce a laminate on the substrate of a thermal spray applied layer and a kinetic spray applied layer.16. The method of claim 1, wherein steps c) and d) comprise positioning a substrate comprising a metal, an alloy, a ceramic, a plastic, a semi-conductor, wood, paper, or mixtures thereof opposite the nozzle.17. The method of claim 1, wherein step a) comprises providing particles comprising a metal, an alloy, a ceramic, a polymer, or mixtures of thereof.18. The method of claim 1, wherein step b) comprises injecting the particles through a tube having an inner diameter of from 0.4 to 3.0 millimeters in diameter.19. The method of claim 1, wherein step b) comprises providing a nozzle having a diverging region with a length of from 60.0 to 400.0 millimeters in length.20. The method of claim 1, wherein step b) comprises providing a nozzle having a throat with a diameter of from 1.5 to 3.5 millimeters.