Plasma coatings comprised of sprayed fibers

Stock material or miscellaneous articles – All metal or with adjacent metals – Embodying fibers interengaged or between layers

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Details

428621, 428937, B32B 700, B32B 1514

Patent

active

045956375

ABSTRACT:
Disclosed is a process for plasma spraying small metal fibers, to adhere them to the surface of a workpiece, and articles made using the process. The process is especially useful for improving the strength of plasma arc coatings, as well as for improving the bonding of plasma arc coatings to substrates. To make an improved ceramic faced metal article, fibers are sprayed onto the workpiece by injecting fibers into the plasma stream external to the plasma gun nozzle. Then, plasma sprayed ceramic particles are caused to surround the fibers as a matrix. The optional interposition of a removable polymer material on the workpiece surface, after the fibers are sprayed but before the ceramic matrix is sprayed, provides an effective way of providing a low stiffness connector between a low thermal expansion coefficient ceramic material and a high expansion coefficient metal substrate. The connector alleviates strains from thermal expansion differences.

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