Coating processes – Spray coating utilizing flame or plasma heat – Continuous feed solid coating material
Patent
1997-03-31
1998-10-13
Bareford, Katherine A.
Coating processes
Spray coating utilizing flame or plasma heat
Continuous feed solid coating material
427456, 219 7614, 21914522, 21914623, 21914624, 2191463, 21914641, C23C 416, C23C 406
Patent
active
058209395
ABSTRACT:
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.
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Cook David James
Joaquin Armando Mateo
Pank Deborah Rose
Popoola Oludele Olusegun
Zaluzec Matthew John
Bareford Katherine A.
Ford Global Technologies Inc.
Malleck Joseph W.
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