Coated nozzles for arc torches

Patent metadata

Field	Value
Publication number	US-12484138-B2
Application number	US-201916593323-A
Country	US
Kind code	B2
Filing date	Oct 4, 2019
Priority date	Oct 4, 2019
Publication date	Nov 25, 2025
Grant date	Nov 25, 2025

Abstract

In one aspect, nozzles for arc torches are described herein comprising refractory coatings for increasing nozzle operational lifetimes via resistance to weld splatter and the associated accumulation of molten metal deposits. In one aspect, a nozzle for an arc torch comprises a first body including a central bore and an exterior surface. A coating is adhered to the exterior surface by thermal spray, physical vapor deposition (PVD), or chemical vapor deposition (CVD), the coating comprising a refractory layer including one or more metallic elements selected from the group consisting of aluminum, silicon and metallic elements of Groups IIIB-VIIIB of the Periodic Table and one or more non-metallic elements selected from Groups IIIA, IVA, VA, and VIA of the Periodic Table.

First claim

The invention claimed is:

1 . A nozzle for an arc torch comprising:
a first body comprising a central bore and an exterior surface; and a coating adhered to the exterior surface by physical vapor deposition (PVD) or chemical vapor deposition (CVD), the coating comprising a refractory layer of Ti 1-x-y Me y Al x N, wherein Me is selected from Groups IVB-VIB of the Periodic Table and x>0, y≥0, and 0.3≤x+y≤0.9.

2 . The nozzle of claim 1 , wherein the refractory layer has thickness of 1 μm to 10 μm.

3 . The nozzle of claim 1 , wherein the refractory layer has a critical load (L c ) of at least 45 kgf.

4 . The nozzle of claim 1 , wherein the refractory layer has a critical load (L c ) of at least 60 kgf.

5 . The nozzle of claim 1 , wherein the exterior surface is formed of copper or copper alloy.

6 . The nozzle of claim 5 , wherein the exterior surface is formed of copper.

7 . The nozzle of claim 1 , wherein y=0 and 0.4≤x≤0.6.

8 . The nozzle of claim 1 , wherein the refractory layer has a surface roughness less than 500 nm.

9 . The nozzle of claim 1 , wherein the nozzle exhibits a continuous welding or plasma cutting lifetime of at least 5 hours.

10 . The nozzle of claim 1 , wherein the nozzle exhibits a continuous welding or plasma cutting lifetime of at least 7 hours.

11 . A method of welding or plasma cutting comprising:
providing an arc torch comprising a nozzle, the nozzle including a first body comprising a central bore and an exterior surface, and a coating adhered to the exterior surface by physical vapor deposition (PVD) or chemical vapor deposition (CVD), the coating comprising a refractory layer of Ti 1-x-y Me y Al x N, wherein Me is selected from Groups IVB-VIB of the Periodic Table and x>0, y≥0, and 0.3≤x+y≤0.9; and welding or plasma cutting a metal or alloy workpiece with the arc torch.

12 . The method of claim 11 , wherein the nozzle has a continuous welding or plasma cutting lifetime greater than twice an uncoated nozzle lifetime, the uncoated nozzle having a construction identical to the coated nozzle.

13 . The method of claim 11 , wherein the refractory layer has thickness of 1 μm to 10 μm.

14 . The method of claim 11 , wherein the refractory layer has a critical load (L c ) of at least 45 kgf.

15 . The method of claim 11 , wherein the refractory layer has a critical load (L c ) of at least 60 kgf.

16 . The method of claim 11 , wherein the exterior surface is formed of copper or copper alloy.

17 . The method of claim 16 , wherein the exterior surface is formed of copper.

18 . The method of claim 11 , wherein y=0 and 0.4≤x≤0.6.

19 . The method of claim 11 , wherein, the refractory layer has a surface roughness less than 500 nm.

20 . A nozzle for an arc torch comprising:
a first body comprising a central bore and an exterior surface; and a coating adhered to the exterior surface by thermal spray, the coating comprising a refractory layer of Ti 1-x-y Me y Al x N, wherein Me is selected from Groups IVB-VIB of the Periodic Table and x>0, y≥0, and 0.3≤x+y≤0.9.

21 . The nozzle of claim 20 , wherein the exterior surface is formed of copper or copper alloy.

22 . The nozzle of claim 21 , wherein the exterior surface is formed of copper.

23 . The nozzle of claim 20 , wherein the coating is a single layer.

Assignees

• Kennametal Inc

Inventors

• Vasinko Robert J
• Zheng Qingjun
• Charlton Corinne
• Kohlscheen Joern

Classifications

• H05H1/3457

  Nozzle protection devices · CPC title

• H05H1/34 Primary

  Details, e.g. electrodes, nozzles · CPC title

• C23C16/34

  Nitrides {(C23C16/303 takes precedence)} · CPC title

• C23C14/0641

  Nitrides (C23C14/0617 takes precedence) · CPC title

• C23C4/10

  Oxides, borides, carbides, nitrides or silicides; Mixtures thereof · CPC title