Open-arc plasma wire spray method and apparatus

Claim 2

Open-arc plasma wire spray apparatus comprising: a plasma-arc torch of the type wherein a thermally ionizable gas is directed past a non-consumable cathode electrode and through the constricted orifice of a nozzle and wherein an arc is established between the non-consumable electrode and the nozzle to initiate and sustain a plasma stream through said constricted orifice and then through a final port in a housing; means for directing a shield gas around said nozzle and through said final port in the housing; a wire guide/contact tip for supporting a positively charged spray wire; and a wire alignment fixture for coupling said wire guide/contact tip to said plasma-arc torch so that the tip of said spray wire is disposed in aid plasma stream outside said final port in the housing, said wire alignment fixture having a first collar section fixed to said torch and a second collar section fixed to the wire guide/contact tip.

Claim 3

An open-arc plasma wire spray torch body having a head section and a handle section of the type wherein a thermally ionizable gas is directed past a non-consumable electrode and through the constricted orifice of a primary nozzle and wherein an arc is established between the non-consumable electrode and the primary nozzle to initiate and sustain a plasma stream through said constricted orifice comprising: a central cathode electrode; first means for coupling negative electrical power to said central electrode; a primary plasma nozzle having a constricted outlet port; first means for coupling positive electrical power to said primary plasma nozzle, said positive electric power being coupled through a resistance to reduce the potential at said primary plasma nozzle; means for directing said thermally ionizable gas past said electrode and through said orifice; second means for coupling negative electrical power to said first means for coupling negative electrical power; second means for coupling positive electrical power to said first means for coupling positive electric power; means for coupling the thermally ionizable gas to said head section; means for supporting a spray wire in front of said constricted outlet port of said primary plasma nozzle in said plasma stream, said spray wire being coupled to positive electric power, said means for supporting a spray wire including a bore in said handle section, a wire guide/contact tip being disposed in said bore, said spray wire being disposed in said wire guide/contact tip, said bore being adapted to allow a gas under pressure to be directed through said bore to cool said wire; a chamber surrounding the constricted outlet port, the tip of said spray wire being disposed within said chamber, said cooling gas being directed from said bore into said chamber to provide a secondary atomizing gas; means for directing a gas under pressure into said chamber to provide a second gas; and said means for providing a chamber including a secondary atomizing nozzle having an outlet port.

Claim 4

An open-arc plasma wire spray torch body having a head section and a handle section of the type wherein a thermally ionizable gas is directed past a non-consumable electrode and through the constricted orifice of a primary nozzle and wherein an arc is established between the non-consumable electrode and the primary nozzle to initiate and sustain a plasma stream through said constricted orifice comprising: a central cathode electrode; first means for coupling negative electrical power to said central electrode; a primary plasma nozzle having a constricted outlet port; first means for coupling positive electrical power to said primary plasma nozzle, said positive electric power being coupled through a resistance to reduce the potential at said primary plasma nozzle; means for directing said thermally ionizable gas past said electrode and through said orifice; second means for coupling negative electrical power to said first means for coupling negative electrical power; second means for coupling positive electrical power to said first means for coupling positive electric power; means for coupling the thermally ionizable gas to said head section; means for supporting a spray wire in front of said constricted outlet port of said primary plasma nozzle in said plasma stream, said spray wire being coupled to positive electric power, said means for supporting a spray wire including a bore in said handle section, a wire guide/contact tip being disposed in said bore, said spray wire being disposed in said wire guide/contact tip, said bore being adapted to allow a gas under pressure to be directed through said bore to cool said wire; a chamber surrounding the constricted outlet port, the tip of said spray wire being disposed within said chamber, said cooling gas being directed from said bore into said chamber to provide a secondary atomizing gas; means for directing a gas under pressure into said chamber to provide a second gas; and said means for providing a chamber including a secondary atomizing nozzle having an outlet port.

Claim 5

Apparatus as recited in claim 2 wherein said secondary atomizing nozzle includes: an inner nozzle distribution ring; an outer nozzle distribution ring, said inner nozzle distribution ring and said outer nozzle distribution ring forming a secondary atomizing gas distribution chamber for directing said cooling gas from said bore into said secondary atomizing nozzle.

Claim 6

An improvement in metal spray apparatus of the type employing a transferred arc between a non-consumable electrode supported in a housing channeled for the streaming of plasma gases at a target and consumable spray material wherein the improvement comprises: means for introducing the consumable spray material in the form of a wire into the plasma stream outside the housing channeled for the streaming of plasma gases, and means for gas cooling said means for introducing the consumable spray material.

Claim 7

An improvement in metal spray apparatus of the type employing a transferred arc between a non-consumable electrode supported in a housing channeled for the streaming of plasma gases at a target and consumable spray material wherein the improvement comprises: means for introducing the consumable spray material in the form of a wire into the plasma stream outside the housing channeled for the streaming of plasma gases, and means for gas cooling said means for introducing the consumable spray material.

Claim 8

Open-arc plasma wire spray apparatus comprising: a plasma-arc torch of the type wherein a thermally ionizable gas is directed past a non-consumable cathode electrode and through the constricted orifice of a nozzle and wherein an arc is established between the non-consumable electrode and the nozzle to initiate and sustain a plasma stream through said constricted orifice and then through a final port in a housing; means for directing a shield gas around said nozzle and through said final port in the housing; a wire guide/contact tip for supporting a positively charged spray wire; and a wire alignment fixture for coupling said wire guide/contact tip to said plasma-arc torch so that the tip of said spray wire is disposed in said plasma stream outside said final port in the housing, and means for gas cooling said wire, said wire guide/contact tip and said wire alignment fixture.

Claim 9

Open-arc plasma wire spray apparatus comprising: a plasma-arc torch of the type wherein a thermally ionizable gas is directed past a non-consumable cathode electrode and through the constricted orifice of a nozzle and wherein an arc is established between the non-consumable electrode and the nozzle to initiate and sustain a plasma stream through said constricted orifice and then through a final port in a housing; means for directing a shield gas around said nozzle and through said final port in the housing; a wire guide/contact tip for supporting a positively charged spray wire; and a wire alignment fixture for coupling said wire guide/contact tip to said plasma-arc torch so that the tip of said spray wire is disposed in said plasma stream outside said final port in the housing, and means for gas cooling said wire, said wire guide/contact tip and said wire alignment fixture.