US2982845A - Electric arc spraying - Google Patents

Electric arc spraying Download PDF

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US2982845A
US2982845A US747938A US74793858A US2982845A US 2982845 A US2982845 A US 2982845A US 747938 A US747938 A US 747938A US 74793858 A US74793858 A US 74793858A US 2982845 A US2982845 A US 2982845A
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Prior art keywords
wire
nozzle
electrode
arc
passage
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US747938A
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Donald M Yenni
William C Mcgill
James W Lyle
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Union Carbide Corp
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Union Carbide Corp
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Priority to US747938A priority Critical patent/US2982845A/en
Priority to ES250328A priority patent/ES250328A2/en
Priority to DK231459AA priority patent/DK103792C/en
Priority to GB2307959A priority patent/GB877095A/en
Priority to DEU6323A priority patent/DE1098636B/en
Priority to FR799600A priority patent/FR76013E/en
Priority to CH353470D priority patent/CH353470A/en
Priority to BE580519A priority patent/BE580519R/en
Priority to NL241118D priority patent/NL241118A/xx
Priority to NL129366D priority patent/NL129366C/xx
Priority to SE06541/59A priority patent/SE337975B/xx
Priority to AT504859A priority patent/AT232352B/en
Application granted granted Critical
Publication of US2982845A publication Critical patent/US2982845A/en
Priority to FR870884A priority patent/FR80463E/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3033Ni as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05BSPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • B05B7/222Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
    • B05B7/224Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material having originally the shape of a wire, rod or the like
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K10/00Welding or cutting by means of a plasma
    • B23K10/02Plasma welding
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05HPLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00Generating plasma; Handling plasma
    • H05H1/24Generating plasma
    • H05H1/26Plasma torches
    • H05H1/32Plasma torches using an arc
    • H05H1/42Plasma torches using an arc with provisions for introducing materials into the plasma, e.g. powder, liquid
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/46Molding using an electrical heat

Definitions

  • This invention relates to electric arc spraying and, more particularly, to transforming material in the form of a rod or wire to a spray.
  • torch wire spraying is accomplished by specifically feeding a consumable wire electrode into the collimated arc effluent inside of the nozzle of the spraying equipment.
  • the consumable wire is positioned in an area of maximum or near maximum concentration of momentum thus resulting in a desirably fine droplet spray of molten coating or welding material.
  • the portion of the nozzle extending beyond the point of wire feed tends to focus and control the droplet spray.
  • the consumable wire electrode can be in electrical contact with the nozzle electrode and thereby receive its electrical power.
  • the consumable wire electrode be electrically insulated from the nozzle electrode in order to maintain higher power to the wire and to take advantage of resistance heating in the wire to increase wire melt-off. It is also preferred that torches having the nozzle section extending downstream from the wire have a diverging nozzle so as to minimize plugging and to reduce possible are pitting of the nozzle at high current levels.
  • the jet-like effluent from the nozzle outlet protects and projects the molten metal from the consumable electrode toward the desired workpiece area.
  • Use of inert gas streams enables the molten metal to be protected from air contamination and results in relatively oxide-free metal deposits having desirable adherent characteristics.
  • Such process and apparatus have been greatly improved, according to this invention, by specifically feeding the consumable wire electrode into the collimated arc efiluent inside of the gas nozzle.
  • This novel method has the primary advantages of improved control over the focusing, positioning, and droplet quality of the molten metal spray.
  • the wire is preferably positioned at or near the point of minimum nozzle cross section thus resulting in maximum or near maximum momentum transfer from the hot high velocity arc gas to the molten coating material.
  • Fig. 1 is a fragmentary view mainly in vertical cross section of apparatus illustrating one form of the invention.
  • Figs. 2, 3, and 4 are similar views of modifications.
  • apparatus A includes a stick electrode 10 positioned in coaxial relation to a nozzle electrode 11. Such electrodes are connected to an electric power supply 12 through leads 13 and 14, respectively.
  • a selected gas stream flows down through the annular space between stick electrode 10 and bore 15 in nozzle electrode 11.
  • Such gas may be any suitable arc gas such as argon, helium, nitrogen, or hydrogen.
  • Some hydrogen in the gas mixture is desired where hydrogen is metallurgically acceptable to increase the wire melt-oil, be cause of increased heat created by the generation of atomic hydrogen in the arc, and its subsequent recombination on or near the spraying material.
  • a consumable wire 16 is fed by rolls 17 through a lateral passage P in the wall of nozzle electrode 11 and into the nozzle passage 18.
  • the wire is shown entering at an acute angle to the horizontal, but this is only a convenience.
  • the vertical posit-ion at which the wire enters is chosen at a point most satisfactory for given equipment size and configuration.
  • the wire thus is positioned as close as possible to the point of maximum arc constriction and maximum momentum concentration.
  • the wire 16 is in electrical contact with nozzle electrode 11 and thus may become an electrode when it projects into nozzle passage 18.
  • the arc 19, which originally passed between electrodes 10 and 11, then tends to transfer in part to wire 16.
  • the molten metal from wire 16 is then projected as a high velocity effluent 20 with the gas stream.
  • the nozzle 11 is cooled below its melting point by passing cooling fluid such as water from inlet 21 through passage 22 to outlet 23.
  • a suitable receiver R is disposed under the apparatus A in the zone into which the spray-containing effluent 20 is discharge
  • the wire feed rate is adjusted in combination with the electrical power to maintain the molten tip of the wire in approximately the center of the nozzle passage. This results in the metal spray being approximately in line with the longitudinal axis of the nozzle passage 18. Too slow a feed rate results in a spray of large particles at an angle to such axis, such angle being located on the side in the direction from which the wire is fed. Increasing the feed rate beyond optimum conditions results in the same spray as with too little feed, except the spray is located on the other side of such axis. Both of these conditions are obviously undesirable.
  • the nozzle electrode and the consumable wire are at the same electrical potential.
  • Such circuit arrangement enables an effective self-regulation to occur in connection with the wire feed which tends to maintain the molten tip of the wire in the approximate center of the .nozzle passage.
  • the wire projects into the longitudinal nozzle passage, it begins to carry increased amounts of current. If it projects beyond the center of the passage, the increased current plus resistance heating along the projected portion of the wire, plus greater exposure to the high energy stream, increases the melt-oil rate, and the wire melts more rapidly back toward the center position. If the wire feed rate slows up and the wire projection decreases, the wire will draw less current and the nozzle electrode will draw more current. The overall effect will be to reduce melt-off rate.
  • the longitudinal nozzle passage extending beyond the wire is effective to focus and control the position of the molten droplet stream.
  • the divergent discharge passage is effective to reduce undesirable plugging caused by deposits of molten metal particles within the nozzle.
  • a divergent passage in the nozzle electrode also spreads the electrode area and reduces current density. This helps reduce erosion at high current levels.
  • a divergent passage in the nozzle electrode also allows supersonic outlet gas velocity to be attained under certain conditions which further accelerates the molten material in the spray to produce higher impact on workpieces and more dense coatings or welds. For the above reasons, it is, therefore, preferred that the nozzle outlet have an increased crosssectional area, as compared to'the area of the nozzle at the point of wire entry.
  • Additional gas shielding'to minimize atmospheric air contamination ofthe eflluent is obtained by introducing shielding gas at the nozzle outlet through a hollow feed device 28 in the shape of the outlet end .of the nozzle.
  • Fig. 2 Presently preferred modification of the present inven tion is shown in Fig. 2.
  • the consumable wire electrode 16 is electrically insulated from nozzle electrode 11 by a tubular electrical insulator 24 mounted in the lateral passage P.
  • the main electrical connections from are power supply 12 are through line 13 to the stick electrode andline 25 to the consumable wire 16.
  • the nozzle electrode 11 is connected to the power supply through a resistance 26 which tends to maintain the nozzle at a lower potential than that of the consumable wire.
  • This apparatus Fig. 2, -may be operated at higher wire feed rates than that of Fig. 1, because higher power levels can be maintained to the wire without damage to the nozzle. This becomes important when wire feed rates as high as 100 lbs./hr. orhigher are desired.
  • a pilot arc is maintained between the stick electrode and the nozzle electrode to effect start-up of the process and also to maintain an are if Wire feed ceases for any reason.
  • the electrical contact from lead 25 to wire- 16 may be positioned externally to the torch in order to increase resistance heating along the Wire.
  • nozzle extension 27 serves the same purpose as the, extended nozzles of Figs. 1 and 2, namely, to help focus and direct the gas-molten particle stream to a. desired point or area and to minimize aircontamination of the molten particles.
  • FIG. 4 A furthermodification of the invention is shown in Fig. 4.
  • the are current from; electrode 10 is divided among nozzle anode 11, consumable wire electrode 16, and workpiece 29 by suitable adjustment of ballast resistors 26 and 30.
  • a A inch diameter NichromeV wire was fed through apassage in the side of the nozzle at 40 inches/minute. Additional hydrogen shielding gas at 50 c.f.h. was introduced at the nozzle outlet. 'The hot gas effluent-and molten metal spray from the wire electrode were then impinged on a rotating /2-inch diameter cold-rolled steel round positioned l-inch from the torch nozzle outlet. The resulting Nichrome-on-steel coating was dense, adherent, had less-than one percent porosity, andless than one percent oxide impurity;
  • the consumable wire electrode was A -inch diameter carbon'steel welding rod fed at 175 inches/minute. Additional hydrogen shielding gas at 50 c.f.h. was introduced at the nozzle outlet. The hot gas eflluent and molten metal spray from the consumable wire electrode were, then, impinged on a rotating /2-inch diameter carbon steel roundIR. positioned l-inch from the torch nozzle. The resulting steelon-steel coating was dense, adherent, had less than 5 percent porosity and less than 1 percent. oxide impurity.
  • cross-sectional shapes of the nozzle passages described above are circular, but other shapes, such as rectangular, square, or oval, for example, may be used Without departing from the invention.
  • Electric arc spraying apparatus comprising, in combination, a nonconsumable electrode, a nozzle electrode having a nozzle. passage containing an arc constricting orifice, means for energizing a high pressure are between said electrodes, means for supplying gas under pressure to said nozzle passage whereby a wall-stabilized arc etfiuent is discharged from said nozzle passage, and means for introducing a consumable wire laterally into said nozzle passage, such wire being fed into-the nozzle pas sage between the inlet to the constricting orifice and the outlet of the nozzle passage, said arc acting to meltthe end of such wire as it is'fed thereto, and the so-melted metal is projected by and with said effiuent in the form of a spray.
  • Electric arc spraying apparatus as defined by claim 1, including means positioned at the outlet of the nozzle passage for introducing a separate stream of shielding gas to protect the spray etlluent from the atmosphere, said means comprising a hollow feed device in the shape of the outlet end of the nozzle.
  • Electric arc spraying apparatus as defined by claim 1, in which such wire is fed into the nozzle passage at the point of maximum constriction, whereby maximum efilective momentum transfer takes place from the arc plasma and gas flow to the melted metal causing minimum particle size and maximum acceleration of the soproduced spray.
  • Electric arc spraying apparatus as de fined by claim 1, in which such wire is fed into the nozzle passage adjacent to the point of maximum constriction, whereby substantial effective momentum transfer takes place from the arc plasma and gas flow to the melted metal causing reduction in particle size and substantial acceleration of the so-produced spray.
  • Electric arc spraying apparatus as defined byclaim 1, including means insulating said. wire from said nozzle electrode within such lateral wire. passage, and means for energizing an are between the end of said wireand said nonconsumable electrode of .higher potentialthan that between said nozzle electrode, and said nonconsumable electrode.
  • Electric arc spraying apparatus asdefined by claim 5, including means for energizinganother are between a workpiece and said nonconsumable electrode to increase the eflfective heating of such workpiece.
  • Electric arc spraying apparatus as'd'efined by claim 1, in which said wire is fed into such efiluent at an acute angle thereto.
  • Electric arc spraying apparatus comprising a nozzle electrode having a gas inlet leading to an arc constricting orifice which discharges in a divergent outlet, a nonconsumable electrode mounted so as to project into such gas inlet in spaced relation to such orifice, means for energizing a high pressure are between said electrodes, means for supplying gas under pressure to said inlet, whereby a wall-stabilized arc efiluent is discharged through said divergent outlet, said nozzle having a lateral wire passage leading to said outlet adjacent such orifice, and means for feding a consumable wire into such efiluent therethrough.
  • Process of arc spraying which comprises energizing a high presure arc consisting of an arc plasma and gas flow between the ends of consumable and nonconsumable electrodes, wall-stabilizing at least a portion of such are to produce a jet-like efiiuent by passing it through a nozzle passage having a constricted orifice portion, and feeding the consumable wire electrode laterally into such nozzle passage and are at a point adjacent such constricted and wall-stabilized portion thereof, producing a spray of melted wire metal which is projected by and in such eflluent, whereby substantial effective momentum transfer takes place from the arc plasma and gas flow to the melted metal causing substantial acceleration of the soproduced spray.
  • Process of are spraying which comprises laterally constricting a high pressure are consisting of arc plasma and gas flow, and feeding a consumable metal wire electrode laterally into such are at the zone of such constriction producing a spray of melted wire metal, whereby maximum effective momentum transfer takes place from the arc plasma and gas flow to the melted metal causing maximum acceleration of the so-produced spray.
  • Electric arc spraying apparatus comprising a nozzle electrode having a gas inlet leading to an arc constricting orifice which discharges in a divergent outlet, at nonconsumable electrode mounted so as to project into such gas inlet in spaced relation to such orifice, means for energizing a high pressure are between said electrodes, means for supplying gas under pressure to said inlet, whereby a wall-stabilized arc efiiuent is discharged through said di vergent outlet, said nozzle having a lateral wire passage leading to such orifice, and means for feeding a consumable wire into such effiuent therethrough.

Description

May 2, 1961 D. M. YENNI ETAL ELECTRIC ARC SPRAYING Filed July 11, 1958 DH S W m 5 H INVENTOPS DONALD M. YENNI WILLIAM C. McGlLL JAMES W. LYLE ATTORNEY v United States Patent Ofiice 2,982,845 Patented May 2, 1961 2,982,845 ELECTRIC ARC SPRAYING Donald M. Yenni, William C. McGill, and James W. Lyle, Indianapolis, Ind., assignors to Union Carbide Corporation, a corporation of New York Filed July 11, 1958, Ser. No. 747,938
12 Claims. (Cl. 219-76) This invention relates to electric arc spraying and, more particularly, to transforming material in the form of a rod or wire to a spray.
According to the invention, are torch wire spraying is accomplished by specifically feeding a consumable wire electrode into the collimated arc effluent inside of the nozzle of the spraying equipment. In this fashion the consumable wire is positioned in an area of maximum or near maximum concentration of momentum thus resulting in a desirably fine droplet spray of molten coating or welding material. The portion of the nozzle extending beyond the point of wire feed tends to focus and control the droplet spray. The consumable wire electrode can be in electrical contact with the nozzle electrode and thereby receive its electrical power.
It is preferred in some cases that the consumable wire electrode be electrically insulated from the nozzle electrode in order to maintain higher power to the wire and to take advantage of resistance heating in the wire to increase wire melt-off. It is also preferred that torches having the nozzle section extending downstream from the wire have a diverging nozzle so as to minimize plugging and to reduce possible are pitting of the nozzle at high current levels.
There is a need in industry for improved methods of conveniently applying metal to clad various workpiece surfaces and to weld articles together. One means previously employed has been to use a high pressure are process of the type disclosed in Patent No. 2,847,555, based on application, Serial No. 539,870, filed on October 11, 1955, by Donald M. Yenni. In such process an arc was struck between a nonconsumable stick-type electrode, such as thoriated tungsten, and a consumable metal wire electrode. A gas stream, relatively inert to the non-consumable electrode, passed along this electrode and flowed through a gas nozzle positioned between the stick electrode and the consumable electrode. The combination of the gas flow and nozzle stabilized and collimated the are energy. The jet-like effluent from the nozzle outlet protects and projects the molten metal from the consumable electrode toward the desired workpiece area. Use of inert gas streams enables the molten metal to be protected from air contamination and results in relatively oxide-free metal deposits having desirable adherent characteristics.
Such process and apparatus have been greatly improved, according to this invention, by specifically feeding the consumable wire electrode into the collimated arc efiluent inside of the gas nozzle. This novel method has the primary advantages of improved control over the focusing, positioning, and droplet quality of the molten metal spray. The wire is preferably positioned at or near the point of minimum nozzle cross section thus resulting in maximum or near maximum momentum transfer from the hot high velocity arc gas to the molten coating material.
In the drawing:
Fig. 1 is a fragmentary view mainly in vertical cross section of apparatus illustrating one form of the invention; and
Figs. 2, 3, and 4 are similar views of modifications.
As shown in Fig. =1, apparatus A includes a stick electrode 10 positioned in coaxial relation to a nozzle electrode 11. Such electrodes are connected to an electric power supply 12 through leads 13 and 14, respectively. A selected gas stream flows down through the annular space between stick electrode 10 and bore 15 in nozzle electrode 11. Such gas may be any suitable arc gas such as argon, helium, nitrogen, or hydrogen. Some hydrogen in the gas mixture is desired where hydrogen is metallurgically acceptable to increase the wire melt-oil, be cause of increased heat created by the generation of atomic hydrogen in the arc, and its subsequent recombination on or near the spraying material.
A consumable wire 16 is fed by rolls 17 through a lateral passage P in the wall of nozzle electrode 11 and into the nozzle passage 18. The wire is shown entering at an acute angle to the horizontal, but this is only a convenience. The vertical posit-ion at which the wire enters is chosen at a point most satisfactory for given equipment size and configuration. The wire thus is positioned as close as possible to the point of maximum arc constriction and maximum momentum concentration. The wire 16 is in electrical contact with nozzle electrode 11 and thus may become an electrode when it projects into nozzle passage 18. The arc 19, which originally passed between electrodes 10 and 11, then tends to transfer in part to wire 16. The molten metal from wire 16 is then projected as a high velocity effluent 20 with the gas stream. The nozzle 11 is cooled below its melting point by passing cooling fluid such as water from inlet 21 through passage 22 to outlet 23. A suitable receiver R is disposed under the apparatus A in the zone into which the spray-containing effluent 20 is discharged.
The wire feed rate is adjusted in combination with the electrical power to maintain the molten tip of the wire in approximately the center of the nozzle passage. This results in the metal spray being approximately in line with the longitudinal axis of the nozzle passage 18. Too slow a feed rate results in a spray of large particles at an angle to such axis, such angle being located on the side in the direction from which the wire is fed. Increasing the feed rate beyond optimum conditions results in the same spray as with too little feed, except the spray is located on the other side of such axis. Both of these conditions are obviously undesirable.
Ideal wire feed rates of 250 inches/minute for steel inches/minute for Nichrome V, and 300 inches/minute for aluminum have resulted with A -inch diameter wire and 10 kw. D.C.S.P. total power. The equipment used for the above conditions had a nozzle throat of 43-inch diameter, and a divergent bore of 30 included angle.
In the modification of Fig. 1 the nozzle electrode and the consumable wire are at the same electrical potential. Such circuit arrangement enables an effective self-regulation to occur in connection with the wire feed which tends to maintain the molten tip of the wire in the approximate center of the .nozzle passage. As the wire projects into the longitudinal nozzle passage, it begins to carry increased amounts of current. If it projects beyond the center of the passage, the increased current plus resistance heating along the projected portion of the wire, plus greater exposure to the high energy stream, increases the melt-oil rate, and the wire melts more rapidly back toward the center position. If the wire feed rate slows up and the wire projection decreases, the wire will draw less current and the nozzle electrode will draw more current. The overall effect will be to reduce melt-off rate.
The longitudinal nozzle passage extending beyond the wire is effective to focus and control the position of the molten droplet stream. The divergent discharge passage is effective to reduce undesirable plugging caused by deposits of molten metal particles within the nozzle. A divergent passage in the nozzle electrode also spreads the electrode area and reduces current density. This helps reduce erosion at high current levels. A divergent passage in the nozzle electrode also allows supersonic outlet gas velocity to be attained under certain conditions which further accelerates the molten material in the spray to produce higher impact on workpieces and more dense coatings or welds. For the above reasons, it is, therefore, preferred that the nozzle outlet have an increased crosssectional area, as compared to'the area of the nozzle at the point of wire entry.
Additional gas shielding'to minimize atmospheric air contamination ofthe eflluent is obtained by introducing shielding gas at the nozzle outlet through a hollow feed device 28 in the shape of the outlet end .of the nozzle.
Presently preferred modification of the present inven tion is shown in Fig. 2. In this form the consumable wire electrode 16 is electrically insulated from nozzle electrode 11 by a tubular electrical insulator 24 mounted in the lateral passage P. The main electrical connections from are power supply 12 are through line 13 to the stick electrode andline 25 to the consumable wire 16. The nozzle electrode 11 is connected to the power supply through a resistance 26 which tends to maintain the nozzle at a lower potential than that of the consumable wire.
This apparatus, Fig. 2, -may be operated at higher wire feed rates than that of Fig. 1, because higher power levels can be maintained to the wire without damage to the nozzle. This becomes important when wire feed rates as high as 100 lbs./hr. orhigher are desired. A pilot arc is maintained between the stick electrode and the nozzle electrode to effect start-up of the process and also to maintain an are if Wire feed ceases for any reason. The electrical contact from lead 25 to wire- 16 may be positioned externally to the torch in order to increase resistance heating along the Wire.
In the modification of the invention shown in Fig. 3, nozzle extension 27 serves the same purpose as the, extended nozzles of Figs. 1 and 2, namely, to help focus and direct the gas-molten particle stream to a. desired point or area and to minimize aircontamination of the molten particles.
A furthermodification of the invention is shown in Fig. 4. The are current from; electrode 10 is divided among nozzle anode 11, consumable wire electrode 16, and workpiece 29 by suitable adjustment of ballast resistors 26 and 30. I
The following examples describe actual use of this invention to apply metal coatings to metallic base plates:
EXAMPLE I Arc torch spraying of Nichrome wire Apparatus of the typeshownin Fig. l-was used with the exception that a straight bore nozzlewas used, .i.e., non-divergent outlet. A gas mixturerof 200 c.f-.h. argon and 13.5 c.f.h. hydrogen passed down around. a As-inch diameter thoriated tungsten stick, electrode, and out through a Aa-inch diameter (non-divergent) passage in the nozzle electrode. Anarc of 75 volts (D.C.S.P.) and 150 amperes was struck between such electrodes. A A inch diameter NichromeV wire was fed through apassage in the side of the nozzle at 40 inches/minute. Additional hydrogen shielding gas at 50 c.f.h. was introduced at the nozzle outlet. 'The hot gas effluent-and molten metal spray from the wire electrode were then impinged on a rotating /2-inch diameter cold-rolled steel round positioned l-inch from the torch nozzle outlet. The resulting Nichrome-on-steel coating was dense, adherent, had less-than one percent porosity, andless than one percent oxide impurity;
EXAMPLE II Arc torch spraying of steel wire Apparatus of the type shown in Fig. 2. was used. A gas mixture of 200 c.f.h. argon and 14 c.f.h. hydrogen passed down around the fis-inch diameter thoriated tungsten stick electrode and out through the passage in a nozzle electrode having a Ms-inch diameter throat and a divergent outlet having 30 angle. An arc of 80 volts (D.C.S.P.) and 110 amperes was struck-between the stick electrode and the consumable Wire electrode plus nozzle electrode. The consumable wire electrode carried 100 amperes while, an .arc current of, IOamperes was supplied to the nozzle electrode. The consumable wire electrode was A -inch diameter carbon'steel welding rod fed at 175 inches/minute. Additional hydrogen shielding gas at 50 c.f.h. was introduced at the nozzle outlet. The hot gas eflluent and molten metal spray from the consumable wire electrode were, then, impinged on a rotating /2-inch diameter carbon steel roundIR. positioned l-inch from the torch nozzle. The resulting steelon-steel coating was dense, adherent, had less than 5 percent porosity and less than 1 percent. oxide impurity.
The cross-sectional shapes of the nozzle passages described above are circular, but other shapes, such as rectangular, square, or oval, for example, may be used Without departing from the invention.
What is claimed is:
1. Electric arc spraying apparatus comprising, in combination, a nonconsumable electrode, a nozzle electrode having a nozzle. passage containing an arc constricting orifice, means for energizing a high pressure are between said electrodes, means for supplying gas under pressure to said nozzle passage whereby a wall-stabilized arc etfiuent is discharged from said nozzle passage, and means for introducing a consumable wire laterally into said nozzle passage, such wire being fed into-the nozzle pas sage between the inlet to the constricting orifice and the outlet of the nozzle passage, said arc acting to meltthe end of such wire as it is'fed thereto, and the so-melted metal is projected by and with said effiuent in the form of a spray.
2. Electric arc spraying apparatus, as defined by claim 1, including means positioned at the outlet of the nozzle passage for introducing a separate stream of shielding gas to protect the spray etlluent from the atmosphere, said means comprising a hollow feed device in the shape of the outlet end of the nozzle.
3. Electric arc spraying apparatus, as defined by claim 1, in which such wire is fed into the nozzle passage at the point of maximum constriction, whereby maximum efilective momentum transfer takes place from the arc plasma and gas flow to the melted metal causing minimum particle size and maximum acceleration of the soproduced spray.
4. Electric arc spraying apparatus, as de fined by claim 1, in which such wire is fed into the nozzle passage adjacent to the point of maximum constriction, whereby substantial effective momentum transfer takes place from the arc plasma and gas flow to the melted metal causing reduction in particle size and substantial acceleration of the so-produced spray.
5. Electric arc spraying apparatus, as defined byclaim 1, including means insulating said. wire from said nozzle electrode within such lateral wire. passage, and means for energizing an are between the end of said wireand said nonconsumable electrode of .higher potentialthan that between said nozzle electrode, and said nonconsumable electrode.
6. Electric arc spraying apparatus, asdefined by claim 5, including means for energizinganother are between a workpiece and said nonconsumable electrode to increase the eflfective heating of such workpiece.
7. Electric arc spraying apparatus, as'd'efined by claim 1, in which said wire is fed into such efiluent at an acute angle thereto.
8. Electric arc spraying aparatus, as defined by claim 1, in which said wire is fed into such efiiluent at a right angle thereto.
9. Electric arc spraying apparatus comprising a nozzle electrode having a gas inlet leading to an arc constricting orifice which discharges in a divergent outlet, a nonconsumable electrode mounted so as to project into such gas inlet in spaced relation to such orifice, means for energizing a high pressure are between said electrodes, means for supplying gas under pressure to said inlet, whereby a wall-stabilized arc efiluent is discharged through said divergent outlet, said nozzle having a lateral wire passage leading to said outlet adjacent such orifice, and means for feding a consumable wire into such efiluent therethrough.
10. Process of arc spraying which comprises energizing a high presure arc consisting of an arc plasma and gas flow between the ends of consumable and nonconsumable electrodes, wall-stabilizing at least a portion of such are to produce a jet-like efiiuent by passing it through a nozzle passage having a constricted orifice portion, and feeding the consumable wire electrode laterally into such nozzle passage and are at a point adjacent such constricted and wall-stabilized portion thereof, producing a spray of melted wire metal which is projected by and in such eflluent, whereby substantial effective momentum transfer takes place from the arc plasma and gas flow to the melted metal causing substantial acceleration of the soproduced spray.
11. Process of are spraying which comprises laterally constricting a high pressure are consisting of arc plasma and gas flow, and feeding a consumable metal wire electrode laterally into such are at the zone of such constriction producing a spray of melted wire metal, whereby maximum effective momentum transfer takes place from the arc plasma and gas flow to the melted metal causing maximum acceleration of the so-produced spray.
12. Electric arc spraying apparatus comprising a nozzle electrode having a gas inlet leading to an arc constricting orifice which discharges in a divergent outlet, at nonconsumable electrode mounted so as to project into such gas inlet in spaced relation to such orifice, means for energizing a high pressure are between said electrodes, means for supplying gas under pressure to said inlet, whereby a wall-stabilized arc efiiuent is discharged through said di vergent outlet, said nozzle having a lateral wire passage leading to such orifice, and means for feeding a consumable wire into such effiuent therethrough.
References Cited in the file of this patent UNITED STATES PATENTS 1,243,795 Apple Oct. 23, 1917 2,522,482 Olzak Sept. 12, 1950 2,686,860 Buck et a1 Aug. 17, 1954 2,770,708 Briggs Nov. 13, 1956 2,791,673 Armand May 7, 1957 2,816,124 Gage Sept. 10, 1957 2,847,555 Yenni Aug. 12, 1958
US747938A 1955-07-26 1958-07-11 Electric arc spraying Expired - Lifetime US2982845A (en)

Priority Applications (13)

Application Number Priority Date Filing Date Title
US747938A US2982845A (en) 1958-07-11 1958-07-11 Electric arc spraying
ES250328A ES250328A2 (en) 1958-07-11 1959-06-24 Procedure for soding and covering articles with arc (Machine-translation by Google Translate, not legally binding)
DK231459AA DK103792C (en) 1958-07-11 1959-06-27 Method for arc machining bodies of electrically conductive material and apparatus for performing the method.
GB2307959A GB877095A (en) 1955-07-26 1959-07-06 Improvements in and relating to arc cladding or arc welding
DEU6323A DE1098636B (en) 1955-07-26 1959-07-06 Method and device for arc welding
FR799600A FR76013E (en) 1955-07-26 1959-07-07 Method and apparatus for archery
CH353470D CH353470A (en) 1955-07-26 1959-07-08 Process for working by melting a part by means of an electric arc and apparatus for its implementation
BE580519A BE580519R (en) 1958-07-11 1959-07-08 Method and apparatus for archery
NL241118D NL241118A (en) 1958-07-11 1959-07-09
NL129366D NL129366C (en) 1958-07-11 1959-07-09
SE06541/59A SE337975B (en) 1958-07-11 1959-07-10
AT504859A AT232352B (en) 1955-07-26 1959-07-10 Method and device for coating or welding with the aid of an electric arc
FR870884A FR80463E (en) 1955-07-26 1961-08-16 Method and apparatus for archery

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US747938A US2982845A (en) 1958-07-11 1958-07-11 Electric arc spraying

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US2982845A true US2982845A (en) 1961-05-02

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BE (1) BE580519R (en)
DK (1) DK103792C (en)
ES (1) ES250328A2 (en)
NL (2) NL129366C (en)
SE (1) SE337975B (en)

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US3064114A (en) * 1959-09-14 1962-11-13 British Oxygen Co Ltd Apparatus and process for spraying molten metal
US3102947A (en) * 1960-12-29 1963-09-03 Air Reduction Arc welding apparatus
US3106631A (en) * 1961-04-21 1963-10-08 Union Carbide Corp Arc torch device
US3109917A (en) * 1959-04-18 1963-11-05 Boehler & Co Ag Geb Hard facing
US3140380A (en) * 1961-09-08 1964-07-07 Avco Corp Device for coating substrates
US3149222A (en) * 1962-08-21 1964-09-15 Giannini Scient Corp Electrical plasma-jet apparatus and method incorporating multiple electrodes
US3183337A (en) * 1961-06-13 1965-05-11 Giannini Scient Corp Electrical plasma-jet spray torch and method
US3197605A (en) * 1961-02-06 1965-07-27 Soudure Autogene Elect Constricted electric arc apparatus
US3277269A (en) * 1964-02-10 1966-10-04 Weltronic Co Method and apparatus for arc welding
US3304402A (en) * 1963-11-18 1967-02-14 Metco Inc Plasma flame powder spray gun
US3312566A (en) * 1962-08-01 1967-04-04 Giannini Scient Corp Rod-feed torch apparatus and method
US3459919A (en) * 1966-04-19 1969-08-05 Union Carbide Corp Multiarc torch energizing method and apparatus
US3494852A (en) * 1966-03-14 1970-02-10 Whittaker Corp Collimated duoplasmatron-powered deposition apparatus
US3524962A (en) * 1967-06-02 1970-08-18 Air Reduction Aspirating plasma torch nozzle
US3914573A (en) * 1971-05-17 1975-10-21 Geotel Inc Coating heat softened particles by projection in a plasma stream of Mach 1 to Mach 3 velocity
US4019011A (en) * 1975-01-27 1977-04-19 Coast Metals, Inc. Method of and apparatus for hard facing poppet valves
US4078097A (en) * 1976-07-09 1978-03-07 International Prototypes, Inc. Metallic coating process
US4122328A (en) * 1976-03-31 1978-10-24 U.S. Philips Corporation Device and welding torch for plasma-mig-welding
US4146773A (en) * 1976-03-31 1979-03-27 U.S. Philips Corporation Welding torch for plasma-mig-welding
US4205215A (en) * 1976-03-31 1980-05-27 U.S. Philips Corporation Method and device for welding in a thermally ionized gas
EP0127985A2 (en) * 1983-06-03 1984-12-12 National Research Development Corporation Arc deposition of metal onto a substrate
US4642440A (en) * 1984-11-13 1987-02-10 Schnackel Jay F Semi-transferred arc in a liquid stabilized plasma generator and method for utilizing the same
GB2227027A (en) * 1989-01-14 1990-07-18 Ford Motor Co Plasma arc spraying of metal onto a surface
US4992337A (en) * 1990-01-30 1991-02-12 Air Products And Chemicals, Inc. Electric arc spraying of reactive metals
US5109150A (en) * 1987-03-24 1992-04-28 The United States Of America As Represented By The Secretary Of The Navy Open-arc plasma wire spray method and apparatus
EP0546121A1 (en) * 1990-08-31 1993-06-16 Flame Spray Ind Inc High velocity electric-arc spray apparatus and method of forming materials.
US5458754A (en) * 1991-04-22 1995-10-17 Multi-Arc Scientific Coatings Plasma enhancement apparatus and method for physical vapor deposition
EP0727504A2 (en) * 1995-02-14 1996-08-21 General Electric Company Plasma coating process for improved bonding of coatings on substrates
US5808270A (en) * 1997-02-14 1998-09-15 Ford Global Technologies, Inc. Plasma transferred wire arc thermal spray apparatus and method
US6706993B1 (en) 2002-12-19 2004-03-16 Ford Motor Company Small bore PTWA thermal spraygun
US20040151843A1 (en) * 2003-02-04 2004-08-05 Ford Global Technologies, Inc, Clearcoat insitu rheology control via uv cured oligomeric additive network system
WO2007016921A1 (en) * 2005-08-08 2007-02-15 Kjellberg Finsterwalde Elektroden Und Maschinen Gmbh Device and method for the plasma-cutting of workpieces with an additional fusible electrode guided between the nozzle and the workpiece
US20070045241A1 (en) * 2005-08-29 2007-03-01 Schneider Joseph C Contact start plasma torch and method of operation
EP2468914A1 (en) 2010-12-23 2012-06-27 Linde Aktiengesellschaft Method and device for arc spraying
US20130011569A1 (en) * 2010-12-23 2013-01-10 Jochen Schein Method and device for arc spraying
US20130086911A1 (en) * 2011-10-05 2013-04-11 General Electric Company Process and apparatus for overlay welding
WO2014106577A1 (en) * 2013-01-04 2014-07-10 Ford-Werke Gmbh Apparatus for thermally coating a surface
WO2017067581A1 (en) 2015-10-20 2017-04-27 Jiangmen Anotech Cookware Manufacturing Company Ltd. Dishwasher-safe induction cookware

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US2816124A (en) * 1954-04-21 1957-12-10 Union Carbide Corp Process for preparing hexaethylcyclotrisiloxane
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Cited By (51)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3109917A (en) * 1959-04-18 1963-11-05 Boehler & Co Ag Geb Hard facing
US3064114A (en) * 1959-09-14 1962-11-13 British Oxygen Co Ltd Apparatus and process for spraying molten metal
US3102947A (en) * 1960-12-29 1963-09-03 Air Reduction Arc welding apparatus
US3197605A (en) * 1961-02-06 1965-07-27 Soudure Autogene Elect Constricted electric arc apparatus
US3106631A (en) * 1961-04-21 1963-10-08 Union Carbide Corp Arc torch device
US3183337A (en) * 1961-06-13 1965-05-11 Giannini Scient Corp Electrical plasma-jet spray torch and method
US3140380A (en) * 1961-09-08 1964-07-07 Avco Corp Device for coating substrates
US3312566A (en) * 1962-08-01 1967-04-04 Giannini Scient Corp Rod-feed torch apparatus and method
US3149222A (en) * 1962-08-21 1964-09-15 Giannini Scient Corp Electrical plasma-jet apparatus and method incorporating multiple electrodes
US3304402A (en) * 1963-11-18 1967-02-14 Metco Inc Plasma flame powder spray gun
US3277269A (en) * 1964-02-10 1966-10-04 Weltronic Co Method and apparatus for arc welding
US3494852A (en) * 1966-03-14 1970-02-10 Whittaker Corp Collimated duoplasmatron-powered deposition apparatus
US3459919A (en) * 1966-04-19 1969-08-05 Union Carbide Corp Multiarc torch energizing method and apparatus
US3524962A (en) * 1967-06-02 1970-08-18 Air Reduction Aspirating plasma torch nozzle
US3914573A (en) * 1971-05-17 1975-10-21 Geotel Inc Coating heat softened particles by projection in a plasma stream of Mach 1 to Mach 3 velocity
US4019011A (en) * 1975-01-27 1977-04-19 Coast Metals, Inc. Method of and apparatus for hard facing poppet valves
US4122328A (en) * 1976-03-31 1978-10-24 U.S. Philips Corporation Device and welding torch for plasma-mig-welding
US4146773A (en) * 1976-03-31 1979-03-27 U.S. Philips Corporation Welding torch for plasma-mig-welding
US4205215A (en) * 1976-03-31 1980-05-27 U.S. Philips Corporation Method and device for welding in a thermally ionized gas
US4078097A (en) * 1976-07-09 1978-03-07 International Prototypes, Inc. Metallic coating process
EP0127985A2 (en) * 1983-06-03 1984-12-12 National Research Development Corporation Arc deposition of metal onto a substrate
EP0127985A3 (en) * 1983-06-03 1985-12-18 National Research Development Corporation Arc deposition of metal onto a substrate
US4642440A (en) * 1984-11-13 1987-02-10 Schnackel Jay F Semi-transferred arc in a liquid stabilized plasma generator and method for utilizing the same
US5109150A (en) * 1987-03-24 1992-04-28 The United States Of America As Represented By The Secretary Of The Navy Open-arc plasma wire spray method and apparatus
GB2227027A (en) * 1989-01-14 1990-07-18 Ford Motor Co Plasma arc spraying of metal onto a surface
US5245153A (en) * 1989-01-14 1993-09-14 Ford Motor Company Depositing metal onto a surface
US4992337A (en) * 1990-01-30 1991-02-12 Air Products And Chemicals, Inc. Electric arc spraying of reactive metals
EP0546121A1 (en) * 1990-08-31 1993-06-16 Flame Spray Ind Inc High velocity electric-arc spray apparatus and method of forming materials.
EP0546121A4 (en) * 1990-08-31 1993-11-03 Flame-Spray Industries, Inc. High velocity electric-arc spray apparatus and method of forming materials
US5458754A (en) * 1991-04-22 1995-10-17 Multi-Arc Scientific Coatings Plasma enhancement apparatus and method for physical vapor deposition
US6139964A (en) * 1991-04-22 2000-10-31 Multi-Arc Inc. Plasma enhancement apparatus and method for physical vapor deposition
EP0727504A2 (en) * 1995-02-14 1996-08-21 General Electric Company Plasma coating process for improved bonding of coatings on substrates
EP0727504A3 (en) * 1995-02-14 1996-10-23 Gen Electric Plasma coating process for improved bonding of coatings on substrates
US5770273A (en) * 1995-02-14 1998-06-23 General Electric Company Plasma coating process for improved bonding of coatings on substrates
US5808270A (en) * 1997-02-14 1998-09-15 Ford Global Technologies, Inc. Plasma transferred wire arc thermal spray apparatus and method
US5938944A (en) * 1997-02-14 1999-08-17 Ford Global Technologies, Inc. Plasma transferred wire arc thermal spray apparatus and method
US6706993B1 (en) 2002-12-19 2004-03-16 Ford Motor Company Small bore PTWA thermal spraygun
US20040151843A1 (en) * 2003-02-04 2004-08-05 Ford Global Technologies, Inc, Clearcoat insitu rheology control via uv cured oligomeric additive network system
US6908644B2 (en) 2003-02-04 2005-06-21 Ford Global Technologies, Llc Clearcoat insitu rheology control via UV cured oligomeric additive network system
US20050148704A1 (en) * 2003-02-04 2005-07-07 Ford Global Technologies, Llc Clearcoat insitu rheology control via uv cured oligomeric additive network system
US7632547B2 (en) 2003-02-04 2009-12-15 Ford Global Technologies, Llc Clearcoat insitu rheology control via UV cured oligomeric additive network system
WO2007016921A1 (en) * 2005-08-08 2007-02-15 Kjellberg Finsterwalde Elektroden Und Maschinen Gmbh Device and method for the plasma-cutting of workpieces with an additional fusible electrode guided between the nozzle and the workpiece
US20070045241A1 (en) * 2005-08-29 2007-03-01 Schneider Joseph C Contact start plasma torch and method of operation
US20130011569A1 (en) * 2010-12-23 2013-01-10 Jochen Schein Method and device for arc spraying
EP2468914A1 (en) 2010-12-23 2012-06-27 Linde Aktiengesellschaft Method and device for arc spraying
US20130086911A1 (en) * 2011-10-05 2013-04-11 General Electric Company Process and apparatus for overlay welding
WO2014106577A1 (en) * 2013-01-04 2014-07-10 Ford-Werke Gmbh Apparatus for thermally coating a surface
CN104955582A (en) * 2013-01-04 2015-09-30 福特全球技术公司 Apparatus for thermally coating a surface
CN104955582B (en) * 2013-01-04 2017-05-17 福特全球技术公司 Apparatus for thermally coating a surface
US10124354B2 (en) 2013-01-04 2018-11-13 Ford Global Technologies, Llc Plasma nozzle for thermal spraying using a consumable wire
WO2017067581A1 (en) 2015-10-20 2017-04-27 Jiangmen Anotech Cookware Manufacturing Company Ltd. Dishwasher-safe induction cookware

Also Published As

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BE580519R (en) 1959-11-03
DK103792C (en) 1966-02-21
NL129366C (en)
SE337975B (en) 1971-08-23
ES250328A2 (en) 1960-01-16
NL241118A (en)

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