US4595637A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Plasma coatings comprised of sprayed fibers
Assignee: RTX Corp
•
Filing: 1983-10-24
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Granted: 1986-06-17
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Expires: 2003-10-24
Abstract
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.
Inventors
- 👤 Harry E. Eaton
- 👤 Richard C. Novak
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 16:23
CPC Classifications
C; C23; C23C; C23C4/00; C23C4/04; Y; Y10; Y10S; Y10S428/00; Y10S428/907; Y10T; Y10T428/00; Y10T428/12; Y10T428/12444; Y10T428/12493; Y10T428/12535
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
64 words
An article comprising a substrate having a surface to which are adhered a multiplicity of fibers, the fibers having been partially melted during thermal spraying thereof onto the surface, the fibers bonded to the surface by the portions thereof which have been melted; and, matrix material spaced apart from the surface of the substrate to provide a gap between the matrix and the surface.
Claim 2
Dependent Claim
64 words
An article comprising a substrate having a surface to which are adhered a multiplicity of fibers, the fibers having been partially melted during thermal spraying thereof onto the surface, the fibers bonded to the surface by the portions thereof which have been melted; and, matrix material spaced apart from the surface of the substrate to provide a gap between the matrix and the surface.
Claim 3
Dependent Claim
16 words
The article of claim 1 characterized by a metal substrate, metal fibers and a ceramic matrix.
Claim 4
Dependent Claim
12 words
The article of claim 1 having a gap spacing of 0.25-12 mm.
Claim 5
Dependent Claim
17 words
The article of claim 1 characterized by fibers having a length-to-diameter ratio of between 6:1 and 15:1.
Claim 6
Dependent Claim
19 words
The article of claim 1 characterized by fibers of 0.1-4 mm length having length-to-diameter ratios between 3:1 and 80:1.
Claim 7
Dependent Claim
75 words
An article comprising a substrate having a surface to which are adhered a multiplicity of fibers, the fibers having been partially melted during thermal spraying of the fibers onto the surface, the fibers bonded to the surface by portions thereof which have been melted; and a layered plasma sprayed matrix material enveloping the fibers, the fibers projecting transverse to the layers of the plasma sprayed matrix material and having on their surfaces a bond coat.
Claim 8
Dependent Claim
75 words
An article comprising a substrate having a surface to which are adhered a multiplicity of fibers, the fibers having been partially melted during thermal spraying of the fibers onto the surface, the fibers bonded to the surface by portions thereof which have been melted; and a layered plasma sprayed matrix material enveloping the fibers, the fibers projecting transverse to the layers of the plasma sprayed matrix material and having on their surfaces a bond coat.
Claim 9
Dependent Claim
59 words
An article comprising a substrate having adhered to its surface a multiplicity of metal fibers, the fibers having been injected into a thermal spraying device and portions surfaces of the fibers having been melted during thermal spraying thereof onto the surface, the fibers bonded to each other and to the substrate surface by the melted portions which have solidified.
Claim 10
Dependent Claim
59 words
An article comprising a substrate having adhered to its surface a multiplicity of metal fibers, the fibers having been injected into a thermal spraying device and portions surfaces of the fibers having been melted during thermal spraying thereof onto the surface, the fibers bonded to each other and to the substrate surface by the melted portions which have solidified.
Claim 11
Dependent Claim
14 words
The article of claim 7 further characterized by a matrix material enveloping the fibers.
Claim 12
Dependent Claim
17 words
The article of claim 7 further characterized by a matrix material comprised of layered plasma sprayed particles.
Claim 13
Dependent Claim
18 words
The article of claim 7 further characterized by fibers projecting transverse to the layers of the plasma coating.
Claim 14
Dependent Claim
22 words
The article of claim 7 further characterized by metal alloy fibers adhered to a metal alloy substrate and a ceramic matrix material.
Claim 15
Dependent Claim
17 words
The article of claim 7 characterized by fibers having a length-to-diameter ratio of between 6:1 and 15:1.
Claim 16
Dependent Claim
19 words
The article of claim 7 characterized by fibers of 0.1-4 mm length having length-to-diameter ratios between 3:1 and 80:1.
Claim 17
Dependent Claim
32 words
The article of claim 7 wherein the portion of the article which comprises the multiplicity of fibers has a density of 10-25% of the bulk density of the metal of the fibers.
Claim 18
Dependent Claim
14 words
The article of claim 7 wherein the fibers are composed of a single material.
Claim 19
Dependent Claim
14 words
The article of claim 15 further characterized by a matrix material enveloping the fibers.
Claim 20
Dependent Claim
17 words
The article of claim 15 further characterized by a matrix material comprised of layered plasma sprayed particles.
Claim 21
Dependent Claim
18 words
The article of claim 15 further characterized by fibers projecting transverse to the layers of the plasma coating.
Claim 22
Dependent Claim
22 words
The article of claim 15 further characterized by metal alloy fibers adhered to a metal alloy substrate and a ceramic matrix material.
Claim 23
Dependent Claim
17 words
The article of claim 15 characterized by fibers having a length-to-diameter ratio of between 6:1 and 15:1.
Claim 24
Dependent Claim
19 words
The article of claim 15 characterized by fibers of 0.1-4 mm length having length-to-diameter ratios between 3:1 and 80:1.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-06-16 | 1989-12-16 | 1990-06-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-06-16 | 1993-12-16 | 1994-06-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-06-16 | 1997-12-16 | 1998-06-17 | $7700.00 | Window Closed / Lapsed |