Device for thermally coating a surface

Patent metadata

Field	Value
Publication number	US-10060020-B2
Application number	US-201314759152-A
Country	US
Kind code	B2
Filing date	Dec 19, 2013
Priority date	Jan 4, 2013
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

The invention relates to a device for thermally coating a surface, which has at least one housing, a cathode, which is designed as a consumable wire and at least one insulation element, wherein the housing has a non-detachable anti-adhesion layer.

First claim

The invention claimed is:

1. A device for thermally coating a surface, comprising:
at least one housing;
a cathode;
an anode designed as a consumable wire; and
at least one insulation element embodied as a nozzle ring,
wherein an outer surface of the entire device comprises an outer surface of the housing and an outer surface of the nozzle ring;
wherein the outer surface of the housing is a non-detachable metallic anti-adhesion surface, and
wherein the outer surface of the nozzle ring is the only insulator on the outer surface of the entire device, and all other insulators of the device are situated within the housing.

2. The device of claim 1 ,
wherein the non-detachable metallic anti-adhesion surface of the housing is composed of polished brass.

3. The device of claim 1 ,
wherein the outer surface of the nozzle ring is oriented away from the cathode and composed of ceramic material polished to a mirror finish.

4. The device of claim 1 ,
wherein the outer surface of the nozzle ring is an anti-adhesion surface which has been polished to a mirror finish.

5. The device of claim 1 ,
wherein the outer surface of the housing has a hard-chrome coating as an anti-adhesion surface.

6. The device of claim 1 ,
wherein the outer surface of the housing has a protective aluminum oxide layer as an anti-adhesion surface.

7. The device of claim 1 ,
wherein the outer surface of the housing has a protective zirconium oxide layer as an anti-adhesion surface.

8. The device of claim 1 ,
wherein the outer surface of the housing has an aluminum layer as an anti-adhesion surface.

9. The device of claim 8 ,
wherein the aluminum layer is oxidized, forming a protective aluminum oxide layer.

10. A device for thermally coating a surface, comprising:
a two-part housing including a main element and a cover element;
a cathode;
an anode;
a primary gas distributor;
a secondary gas distributor; and
a nozzle ring having a polished insulating outer surface oriented away from the cathode,
wherein the anode is designed as a consumable wire and is guided into a secondary gas nozzle by means of a wire guide;
wherein the two-part housing is configured to accommodate the wire guide completely within the main element thereof;
wherein a primary gas nozzle is mounted in a centered manner on the primary gas distributor with the secondary gas distributor connected in parallel;
wherein an outer surface of the entire device comprises an outer surface of the two-part housing and the outer surface of the nozzle ring;
wherein the outer surface of the two-part housing is a non-detachable metallic anti-adhesion surface; and
wherein the outer surface of the nozzle ring is the only insulator on the outer surface of the entire device, and all other insulators of the device are situated within the housing.

11. The device of claim 10 , wherein the primary gas nozzle has openings arranged radially in one plane on a side oriented toward the secondary gas nozzle.

12. The device of claim 11 , wherein the nozzle ring is formed from an electrically and thermally insulating element, and wherein the primary gas nozzle directs gas through a central opening of the nozzle ring.

13. The device of claim 12 , wherein the nozzle ring further comprises a plurality of holes centrally arranged in a common plane.

14. The device of claim 12 , wherein the nozzle ring further comprises each of an annular slot and a plurality of holes tangentially arranged along a plurality of planes.

15. The device of claim 13 , wherein the nozzle ring further comprises each of an annular slot and a plurality of tangential labyrinth holes.

16. A method for thermally coating a surface, comprising:
striking an electric arc directly between a cathode and an anode of a thermal coating device, wherein said anode is a consumable wire configured to be guided by a wire guide accommodated completely within a housing of the device;
flowing a first process gas stream around the electric arc from a primary gas nozzle; and
flowing a second process gas stream around the first process gas stream,
wherein the first process gas stream is flowed through a plurality of holes or slots in the primary gas nozzle, arranged radially thereon in a first common plane, said holes oriented away from the cathode,
wherein the second process gas stream is flowed through a nozzle ring having an insulating outer surface which is polished to a mirror finish, said nozzle ring further including a central opening through which the first process gas stream from the primary gas nozzle flows,
wherein an outer surface of the entire device comprises an outer surface of the housing of the device and the outer surface of the nozzle ring,
wherein the outer surface of the housing is a non-detachable metallic anti-adhesion surface, and
wherein the outer surface of the nozzle ring is the only insulator on the outer surface of the entire device, and all other insulators of the device are situated within the housing.

17. The method of claim 16 , wherein flowing the second process gas stream from the nozzle ring includes atomizing a molten portion of the anode and accelerating said molten portion away from the cathode in a direction of the electric arc.

18. The method of claim 16 , wherein the first process gas stream is a noble gas stream produced in a continuous manner, and wherein the second process gas stream is an air stream produced in a pulse manner.

19. The method of claim 16 , wherein flowing the second process gas stream through the nozzle ring further includes flowing the second process gas stream through each of an annular slot extending in a first plane of the nozzle ring and a plurality of tangentially arranged holes at a second common plane of the nozzle ring.

20. The device of claim 10 , wherein the two-part housing has a predominantly circular cross-section which is flattened only in a region of the nozzle ring, and wherein there is an oblique transition from a portion of the two-part housing having a circular cross-section of the two-part housing to a plane in which the nozzle ring is arranged.

Assignees

• Ford Global Tech Llc

Inventors

• Verpoort Clemens Maria
• Schramm Leander
• Hauser Enrico

Classifications

• C23C4/131 Primary

  Wire arc spraying · CPC title

• B05B15/50

  Arrangements for cleaning; Arrangements for preventing deposits, drying-out or blockage; Arrangements for detecting improper discharge caused by the presence of foreign matter · CPC title

• B05B13/0636

  by means of rotatable spray heads or nozzles · CPC title

• B05B7/224

  the material having originally the shape of a wire, rod or the like · CPC title

• C23C4/125 Primary

  Chemistry & Metallurgy · mapped topic