Patent US4992337A successfully refreshed from Google Patents.
US4992337A
Expired / Lapsed
US
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Electric arc spraying of reactive metals
Assignee: Air Products and Chemicals Inc
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Filing: 1990-01-30
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Granted: 1991-02-12
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Expires: 2010-01-30
Abstract
Abstract An improved electric arc spray process for the deposition of reactive metals is disclosed which utilizes compressed inert gases for atomization. The improved process utilizes argon, nitrogen, carbon dioxide, sulfur hexafluoride, or mixtures thereof supplied to the arc spray gun such that the mass ratio of the wire feed rate to the gas feed rate is greater than 0.10. The process can be used to coat various substrates with metals or alloys comprising magnesium, zinc, lithium, and other reactive metals. The process is useful for the application of cathodic corrosion protective coatings on various substrates.
Inventors
- 👤 John J. Kaiser
- 👤 Edward A. Hayduk, Jr.
- 👤 Zbigniew Zurecki
- 👤 Robert B. Swan
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 17:22
CPC Classifications
B; B23; B23K; B23K9/00; B23K9/04; C; C23; C23C; C23C4/00; C23C4/12; B05; B05B; B05B7/00; B05B7/16; B05B7/22; B05B7/222; B05B7/224; Y; Y10; Y10S; Y10S428/00; Y10S428/922; Y10S428/9335; Y10S428/937; Y10T; Y10T428/00; Y10T428/12; Y10T428/12493; Y10T428/12681; Y10T428/12729; Y10T428/12771; Y10T428/12785; Y10T428/12792
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
155 words
A method for applying a metallic coating to a substrate by electric arc spraying comprising: (a) forming an electric arc between two metallic wires in an electric arc spray gun, at least one of said wires comprising one or more reactive metals, thereby causing said wires to melt; and (b) directing pressurized inert gas across said arc to form molten metal droplets and propel said droplets onto said substrate to solidify and form said metallic coating, wherein the mass ratio of the feed rate of said wires into said arc to the feed rate of said inert gas is greater than 0.10; whereby the use of said inert gas shields said molten metal droplets from air and minimizes oxidation and vaporization of said reactive metal, and whereby the use of said inert gas in place of air allows a higher mass feed rate of said metallic wires through said gun at a constant gun power.
Claim 2
Independent Claim
155 words
A method for applying a metallic coating to a substrate by electric arc spraying comprising: (a) forming an electric arc between two metallic wires in an electric arc spray gun, at least one of said wires comprising one or more reactive metals, thereby causing said wires to melt; and (b) directing pressurized inert gas across said arc to form molten metal droplets and propel said droplets onto said substrate to solidify and form said metallic coating, wherein the mass ratio of the feed rate of said wires into said arc to the feed rate of said inert gas is greater than 0.10; whereby the use of said inert gas shields said molten metal droplets from air and minimizes oxidation and vaporization of said reactive metal, and whereby the use of said inert gas in place of air allows a higher mass feed rate of said metallic wires through said gun at a constant gun power.
Claim 3
Dependent Claim
26 words
The method of claim 1 wherein said reactive metal is selected from the group consisting of magnesium, zinc, lithium, bismuth, cadmium, calcium, sodium, and mixtures thereof.
Claim 4
Independent Claim
27 words
The method of claim.1 wherein at least one of said wires comprises a metal selected from the group consisting of aluminum, iron, copper, nickel, and alloys thereof.
Claim 5
Dependent Claim
25 words
The method of claim 1 wherein said inert gas is selected from the group consisting of argon, nitrogen, carbon dioxide, sulfur hexafluoride, and mixtures thereof.
Claim 6
Dependent Claim
18 words
The method of claim 1 wherein the pressure of said inert gas is less than about 40 psig.
Claim 7
Dependent Claim
20 words
The method of claim 1 wherein the pressure of said inert gas is between about 15 psig and 40 psig.
Claim 8
Dependent Claim
17 words
The method of claim 1 wherein the voltage across said arc is less than about 30 volts.
Claim 9
Dependent Claim
18 words
The method of claim 1 wherein the voltage across said arc is between about 20 and 28 volts.
Claim 10
Dependent Claim
32 words
The method of claim 1 wherein said substrate is selected from the group consisting of steel, galvanized steel, aluminized steel, aluminum, aluminum alloys, copper, copper alloys, ceramic material, polymeric material, and paper.
Claim 11
Dependent Claim
163 words
A metal coated substrate comprising a substrate and a metallic coating on at least one surface thereof, said metallic coating being formed by: (a) forming an electric arc between two metallic wires in an electric arc spray gun, at least one of said wires comprising one or more reactive metals, thereby causing said wires to melt; and (b) directing pressurized inert gas across said arc to form molten metal droplets and propel said droplets onto said substrate to solidify and form said metallic coating, wherein the mass ratio of the feed rate of said wires into said arc to the feed rate of said inert gas is greater than 0.10; whereby the use of said inert gas shields said molten metal droplets from air and minimizes oxidation and vaporization of said reactive metal, and whereby the use of said inert gas in place of air allows a higher mass feed rate of said metallic wires through said gun at a constant gun power.
Claim 12
Dependent Claim
163 words
A metal coated substrate comprising a substrate and a metallic coating on at least one surface thereof, said metallic coating being formed by: (a) forming an electric arc between two metallic wires in an electric arc spray gun, at least one of said wires comprising one or more reactive metals, thereby causing said wires to melt; and (b) directing pressurized inert gas across said arc to form molten metal droplets and propel said droplets onto said substrate to solidify and form said metallic coating, wherein the mass ratio of the feed rate of said wires into said arc to the feed rate of said inert gas is greater than 0.10; whereby the use of said inert gas shields said molten metal droplets from air and minimizes oxidation and vaporization of said reactive metal, and whereby the use of said inert gas in place of air allows a higher mass feed rate of said metallic wires through said gun at a constant gun power.
Claim 13
Dependent Claim
28 words
The metal coated substrate of claim 10 wherein said reactive metal is selected from the group consisting of magnesium, zinc, lithium, bismuth, cadmium, calcium, sodium, and mixtures thereof.
Claim 14
Dependent Claim
30 words
The metal coated substrate of claim 10 wherein at least one of said wires comprises a metal selected from the group consisting of aluminum, iron, copper, nickel, and alloys thereof.
Claim 15
Dependent Claim
20 words
The metal coated substrate of claim 10 wherein the pressure of said inert gas is less than about 40 psig.
Claim 16
Dependent Claim
23 words
The metal coated substrate of claim 10 wherein the pressure of said inert gas is between about 15 psig and about 40 psig.
Claim 17
Dependent Claim
19 words
The metal coated substrate of claim 10 wherein the voltage across said arc is less than about 30 volts.
Claim 18
Dependent Claim
34 words
The metal coated substrate of claim 10 wherein said substrate is selected from the group consisting of steel, galvanized steel, aluminized steel, aluminum, aluminum alloys, copper, copper alloys, ceramic material, polymeric material, and paper.
Claim 19
Dependent Claim
18 words
The metal coated substrate of claim 10 wherein said metallic coating provides cathodic corrosion protection for said substrate.
Claim 20
Independent Claim
157 words
A method for applying a metallic coating to a substrate by electric arc spraying comprising: (a) forming an electric arc between two metallic wires in an electric arc spray gun, at least one of said wires comprising one or more less reactive metals, thereby causing said wires to melt; and (b) directing pressurized inert gas across said arc to form molten metal droplets and propel said droplets onto said substrate to solidify and form said metallic coating, wherein the mass ratio of the feed rate of said wires into said arc to the feed rate of said inert gas is greater than 0.10; whereby the use of said inert gas shields said molten metal droplets from air and minimizes oxidation and vaporization of said less reactive metal, and whereby the use of said inert gas in place of air allows a higher mass feed rate of said metallic wires through said gun at a constant gun power.
Claim 21
Independent Claim
157 words
A method for applying a metallic coating to a substrate by electric arc spraying comprising: (a) forming an electric arc between two metallic wires in an electric arc spray gun, at least one of said wires comprising one or more less reactive metals, thereby causing said wires to melt; and (b) directing pressurized inert gas across said arc to form molten metal droplets and propel said droplets onto said substrate to solidify and form said metallic coating, wherein the mass ratio of the feed rate of said wires into said arc to the feed rate of said inert gas is greater than 0.10; whereby the use of said inert gas shields said molten metal droplets from air and minimizes oxidation and vaporization of said less reactive metal, and whereby the use of said inert gas in place of air allows a higher mass feed rate of said metallic wires through said gun at a constant gun power.
Claim 22
Dependent Claim
24 words
The method of claim 18 wherein said less reactive metal is selected from the group consisting of aluminum, iron, copper, nickel, and alloys thereof.
Claim 23
Dependent Claim
25 words
The method of claim 18 wherein said inert gas is selected from the group consisting of argon, nitrogen, carbon dioxide, sulfur hexafluoride, and mixtures thereof.
Claim 24
Dependent Claim
21 words
The method of claim 18 wherein the pressure of said compressed inert gas is between about 15 psig and 40 psig.
Claim 25
Dependent Claim
17 words
The method of claim 18 wherein the voltage across said arc is less than about 30 volts.
Claim 26
Dependent Claim
32 words
The method of claim 18 wherein said substrate is selected from the group consisting of steel, galvanized steel, aluminized steel, aluminum, aluminum alloys, copper, copper alloys, ceramic material, polymeric material, and paper.
Claim 27
Dependent Claim
168 words
A metal coated substrate comprising a substrate and a metallic coating on at least one surface thereof, said metallic coating being formed by: (a) forming an electric arc between two metallic wires in an electric arc spray gun, at least one of said wires comprising one or more less reactive metals, thereby causing said wires to melt; and (b) directing pressurized inert gas across said arc to form molten metal droplets and propel said droplets onto said substrate to solidify and form said metallic coating, wherein the mass ratio of the feed rate of said wires into said arc to the feed rate of said inert gas is greater than 0.10; whereby the use of said pressurized inert gas shields said molten metal droplets from air and minimizes oxidation and vaporization of said less reactive metal, and whereby the use of said pressurized inert gas in place of pressurized air allows a higher mass feed rate of said metallic wires through said gun at a constant gun power.
Claim 28
Dependent Claim
168 words
A metal coated substrate comprising a substrate and a metallic coating on at least one surface thereof, said metallic coating being formed by: (a) forming an electric arc between two metallic wires in an electric arc spray gun, at least one of said wires comprising one or more less reactive metals, thereby causing said wires to melt; and (b) directing pressurized inert gas across said arc to form molten metal droplets and propel said droplets onto said substrate to solidify and form said metallic coating, wherein the mass ratio of the feed rate of said wires into said arc to the feed rate of said inert gas is greater than 0.10; whereby the use of said pressurized inert gas shields said molten metal droplets from air and minimizes oxidation and vaporization of said less reactive metal, and whereby the use of said pressurized inert gas in place of pressurized air allows a higher mass feed rate of said metallic wires through said gun at a constant gun power.
Claim 29
Dependent Claim
26 words
The metal coated substrate of claim 24 wherein said less reactive metal is selected from the group consisting of aluminum, iron, copper, nickel, and alloys thereof;
Claim 30
Dependent Claim
27 words
The metal coated substrate of claim 24 wherein said inert gas is selected from the group consisting of argon, nitrogen, carbon dioxide, sulfur hexafluoride, and mixtures thereof.
Claim 31
Dependent Claim
23 words
The metal coated substrate of claim 24 wherein the pressure of said compressed inert gas is between about 15 psig and 40 psig.
Claim 32
Dependent Claim
19 words
The metal coated substrate of claim 24 wherein the voltage across said arc is less than about 30 volts.
Claim 33
Dependent Claim
34 words
The metal coated substrate of claim 24 wherein said substrate is selected from the group consisting of steel, galvanized steel, aluminized steel, aluminum, aluminum alloys, copper, copper alloys, ceramic material, polymeric material, and paper.
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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) | 1994-02-11 | 1994-08-13 | 1995-02-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-02-11 | 1998-08-13 | 1999-02-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-02-11 | 2002-08-13 | 2003-02-12 | $7700.00 | Window Closed / Lapsed |