U.S. patent number 3,591,759 [Application Number 04/835,876] was granted by the patent office on 1971-07-06 for method of depositing heat fusible material and apparatus therefor.
This patent grant is currently assigned to Sealectro Corporation. Invention is credited to Mille Stand.
United States Patent |
3,591,759 |
Stand |
July 6, 1971 |
METHOD OF DEPOSITING HEAT FUSIBLE MATERIAL AND APPARATUS
THEREFOR
Abstract
A plasma spray device is described which can be used to deposit
heat fusible powdered material onto a substrate to form a
continuous film. An electric arc is formed between two electrodes
to provide a hot gas plasma which is projected through a nozzle.
Powdered fluent material is added to the laminar flowing plasma and
is carried on the surface of the plasma during the passage of the
plasma through an enlarged nozzle, the powder converging at the tip
of the plasma jet. The heat from the arc forms the hot plasma and
the powdered material is melted so that the material coalesces to
form a continuous film when it strikes the substrate.
Inventors: |
Stand; Mille (New York,
NY) |
Assignee: |
Sealectro Corporation
(N/A)
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Family
ID: |
25270685 |
Appl.
No.: |
04/835,876 |
Filed: |
June 4, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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581594 |
Sep 23, 1966 |
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536229 |
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Current U.S.
Class: |
219/76.16;
219/75; 219/121.47 |
Current CPC
Class: |
B05B
7/226 (20130101); H05H 1/42 (20130101); H05H
1/34 (20130101); H05H 1/3478 (20210501); H05H
1/3484 (20210501) |
Current International
Class: |
B05B
7/16 (20060101); B05B 7/22 (20060101); H05H
1/26 (20060101); H05H 1/42 (20060101); H05H
1/34 (20060101); B23k 009/16 (); B23k 009/04 () |
Field of
Search: |
;219/76,75,121P |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Truhe; J. V.
Assistant Examiner: Bender; L. H.
Parent Case Text
This is a continuation-in-part of application, Ser. No. 581,594,
filed Sept. 23, 1966, which was a continuation-in-part of
application, Ser. No. 536,229, both abandoned.
Claims
What I claim is:
1. A plasma spray device comprising an electrode assembly including
a conical central electrode and a conical recess electrode in axial
alignment, means for forcing an ionizable gas over the surface of
the conical electrode and through the conical recess electrode to
form a laminar flowing plasma between the two electrodes, a hollow
passageway associated with the recess electrode and haVing an open
end spaced from the electrodes to form a nozzle for the expulsion
of the laminar plasma, said hollow passageway also formed with an
annular abrupt step between the electrodes and the outlet nozzle
which increases the diameter of the passageway to thereby produce a
subregion of turbulence in the laminar flowing plasma adjoining the
inside surface of the cylindrical passageway, conduits for carrying
fluent particles to the plasma, said conduits having their exit
ports in the hollow passageway at its largest diameter adjoining
said abrupt step and disposed so as to direct the particles onto
the surface of the laminar flowing plasma, gas injection means
around the conical central electrode which includes a plurality of
conduits spaced around the said conical central electrode and
angularly disposed so as to direct the gas to travel through the
space between said conical central electrode and said conical
recess electrode, the cone angle of the recessed electrode being
smaller than the cone angle of the conical central electrode and
the difference between the two angles being within the range of
10.degree. to 30.degree., and electrical means connected to the two
electrodes for forming an electrical arc therebetween.
2. A device according to claim 1 in which the inside surface of
said hollow passageway is an alloy of iron and nickel.
3. A device according to claim 1 in which said conduits spaced
around the conical central electrode are formed in an insulated
disc positioned around the support for the conical electrode.
4. A device according to claim 1 wherein the said central electrode
has a conical angle of approximately 120.degree., and said recess
electrode has a conical angle of approximately 90.degree., and said
hollow passageway gradually diminishes from the electrode end to
said annular step.
5. A method of depositing a heat fusible material on a substrate
comprising creating a plasma in a laminar flowing gas in a
generally cylindrical confined region by an electric discharge
between two electrodes, injecting the gas into said region in
laminar flow through an annular constriction of gradually changing
dimensions adjoining said electrodes, passing the plasma through a
constricted conduit while maintaining laminar flow, expanding the
plasma at the end of said constricted conduit to produce a
subregion of turbulence as a result of the sudden change in
diameter of the conduit, said turbulence restricted to the surface
of the plasma stream, projecting at least one stream of fluidized
heat fusible material into said subregion of turbulence for
conveying the material by the plasma stream to a substrate to be
coated.
6. A method according to claim 5 in which the confined region is
defined by two conical concentric electrode surfaces with the cone
angle of one being different that that of the other.
7. A method according to claim 6 in which the constricted conduit
is of gradually changing diameters.
8. A method according to claim 7 in which the cone angle of the
inner electrode is greater than that of the other electrode.
9. A method according to claim 6 in which the cone angle of the
inner cone surface is greater than that of the outer cone surface
and the difference is between 10.degree. and 30.degree..
10. A method according to claim 9 in which said confined region is
enclosed by an envelope of an alloy that is nonreactive with the
ionized gas and the heat fusible material.
11. A method according to claim 9 in which the heat fusible
material is PTFE, said alloy envelope being high in nickel, and the
ionized gas containing significant amounts of nitrogen.
12. A method according to claim 9 in which said fluidized particles
have a major dimension within the range of 30 to 50 microns and
having generally spherical shape.
Description
This invention relates in general to the deposition of heat fusible
material on a substrate and the apparatus for so depositing and,
more particularly, to a method and apparatus of so depositing using
a plasma flame.
In modern day technology there is a continuing demand for surface
treatments of various materials to provide a property to the
surface that is not inherent in the base material. Typical of such
desired surface characteristics are resistance to corrosion,
coloring, smoothness to promote easier uniform flow of a fluid
thereover, a parting agent for molding, and the like.
In the typical attempts to obtain coatings on substrates,
pulverulent materials having the properties desired in the coating
are somehow attached to the surface to be coated. This has been
done chemically in which the material may be provided in a solvent,
but more often than not, the pulverulent material has been
attempted to be attached to the substrate by heat.
The desired effect is to have the coating firmly adhered to the
substrate so as to resist cracking, chipping or spalling.
The present invention provides a method of coating a substrate by
depositing a heat fusible material thereon in which there is first
created a plasma in a laminar flowing gas in a generally
cylindrical confined region, with the gas flowing into such region
in laminar flow in a converging annular stream about an electrode
so that there is created a laminar flowing plasma. This laminar
flowing plasma is constricted during approximately the first half
of the laminar flow in the region and then is abruptly expanded to
produce a subregion of turbulence around the outer surface of the
jet only, leaving the main stream of the plasma to continue to flow
in a laminar manner.
At the turbulent subregion, fluidized heat fusible material is
added to the jet and carried on its surface, converging at the tip
of the jet, and being melted by the heat of the plasma within that
distance and then applied to a workpiece to be coated. It is
necessary to create the subregion of turbulence at the surface of
the jet in order to pick up the powdered material. Otherwise, the
laminar flowing plasma produces a pressure within the nozzle and
prevents the entry of the powdered material. The abrupt expansion
causes a pressure drop, drawing the fusible material into the
nozzle and carrying it along on the surface of the laminar flowing
plasma.
The invention further provides that the converging annular gas
stream that flows around the electrode have a boundary in the form
of two constricting cones, with the cone angle of the inner one
being greater than the outer one and preferably in the range of
10.degree. to 30.degree. difference.
The invention also contemplates a plasma spray device in which
there is an electrode assembly having a central electrode
surrounded by a cooled housing through which gas passes to provide
an annular blanket of gas over the electrode. Gas is admitted to
the spray device upstream from the arc electrodes in an annular
space which contains a collar having a plurality of spaced holes
for creating a laminar flow through the remainder of the spray
device. The passageway of the nozzle is generally cylindrical and
has at least one fluidized particle inlet through the wall of the
nozzle while having at the inlet end an inwardly finely tapered
constricting portion that terminates abruptly in a large expansion
portion.
The invention additionally calls for the introduction of means to
introduce the heat fluidized fusible material into the passageway
of the nozzle at a position adjacent the termination of the
constricting portion thereof.
The various features of novelty which characterize the invention
are pointed out with particularity in the claims annexed to and
forming a part of this specification, but for a better
understanding of the invention, its operating advantages and
specific objects obtained by its use, reference should be had to
the detailed explanations of the preferred embodiment of the
invention along with the illustrations in the accompanying
drawings.
In the drawings:
FIG. 1 is a vertical section through a plasma spray device
embodying the present invention; and
FIG. 2 is a fragmented partially schematic illustration of the
angle relationship between the electrode and the nozzle of the
present invention .
It has been discovered that if a plasma is created in laminar
flowing gas i.e., flowing gas having a Reynold's number of less
than 2,200, that the noise level and the power consumption by
plasma flame spraying can be considerably reduced. This invention
adds to that discovery by a further finding that the mixing of
pulverulent material in the plasma flame, and the general stability
of the flame is improved; and the power consumption is further
reduced in a more stable flame when the plasma flame is slightly
compressed for a portion of its length while maintaining laminar
flow, if at the end of such constriction or compression there is an
abrupt increase in flow area.
An example of a plasma spray device utilizing this principle is
shown in Figure 1 wherein there is an electrode assembly 10 having
a cooled central electrode 12 and an elongated generally
cylindrical cooled electrode nozzle 14 having a longitudinal
passageway 16 therethrough. A power supply means 18 is arranged to
deliver power through the leads 20, 22 to the nozzle electrode and
central electrode respectively.
A cylindrical wall 24 surrounds the central electrode 12 to form an
annular gas chamber 26 to which a gas may be delivered by a line
28. At one end of the chamber 26 there is an annular gas
distributor having a multiplicity of distributing holes 30 placed
therein at an angle toward the central axis of the central
electrode so that the centerlines of the holes 30 converge at a
point along the central axis.
The passageway 16 has at its inlet end a generally conical recess
32 while the interior wall of the nozzle 14 that forms the
passageway 16 has a converging or inwardly finely tapered
constricting portion 16A running from the maximum diameter at the
electrodes to the junction 16B in the center portion thereof (see
Figure 1). The passageway 16 of the nozzle 14 abruptly increases in
diameter at the point 16B to provide a larger generally uniform
diameter passageway 16C for the outlet or expansion portion of the
nozzle 14.
The central electrode 12 has a conically shaped end 12A which is
positioned within the conical inlet 32 to the passageway 16 so that
it is coaxial with the centerline of such passageway, and forms, in
conjunction with the conical recessed portion 32, the boundary of
an annular converging nozzle which encloses the gas stream flowing
from the distributing holes 30. It should be noted that the cone
angle of the conical electrode end 12A is greater than the cone
angle of the plane of the nozzle inlet 32, i.e., as seen in Figure
2, angle A is greater than angle B.
At the center portion of the nozzle electrode 14 there is a
plurality of powder inlets 34 to generally L-shaped passages 36,
the outlet end of which opens into the longitudinal passageway 16
at the juncture point 16B of the constricting section 16A and the
expansion portion 16C. Further, the centerlines of the outlets 36
are such that they are tangent to an imaginary concentric circle of
a lesser diameter than the bounding walls of the passage 16C so
that the fluidized powder is applied to the plasma stream at an
angle to the nozzle axis and is thereby carried on the surface of
the gas stream rather than being injected into the body of the
moving gas. The powder, when applied in this manner rides on the
surface of the jet and converges at the tip.
The operation of the spray device is as follows: a plasma producing
gas, i.e., a gas which may be ionized, is introduced into the inlet
chamber 26 by the conduit 28 under pressure. The gas is then
directed inwardly in a generally converging annular stream by the
converging distributing passages 30 whereupon the converging
annular stream flows between the central electrode 12A and the
nozzle conical recess 32 at which point the stream becomes a
constricted converging annular stream of gas. Thereafter, this
stream of gas flows along the passageway 16 at a velocity wherein
its Reynold's number is in the laminar flow region. Due to the
slight or finely tapered shape of the constricting portion 16A of
the passageway 16, the laminar flowing gas has its velocity
increased while being maintained in the laminar flow condition. The
plasma is caused to be set up in the passageway 16 upon the
application of power across electrodes 12 and 14 and forms, as
indicated in Figure 1, a generally uniform cylindrical plasma
having a slight annular enveloping layer of flowing gas.
Upon reaching the juncture point 16B wherein the nozzle flow area
suddenly increases, the laminar flowing plasma continues, but in
appearance has a gradual or narrow cone angle of conical shape. The
abrupt change in cross section marks the point where the plasma
flame begins to diminish in diameter and appears to create a
stability position. Fluidized pulverized material which is heat
fusible is introduced into passages 36 and due to the entrance
angle of these passages, the pulverized material is forced into a
revolving path as it is carried along the nozzle 16C. The powdered
material is carried through the supply conduits (not shown) and the
passages 36 by a compressed gas which should be an ionizable gas
and preferably of the same type as introduced into chamber 26. The
mixture of powdered material and gas entering at point 16B flows
through the nozzle and forms a cone around the plasma flame as the
material is carried to the workpiece (not shown).
In Figure 2 there is illustrated in simple form just those portions
of the central electrode 12A and the nozzle to illustrate the
relationship between the cone angle A of the central electrode 12
and the cone angle B of the recess 32 of the nozzle 14. Performance
of the plasma spray device has indicated that the relationship
between angle A and angle B greatly affects the length, the
diameter, and the stability of the plasma flame within the
passageway 16 of the nozzle. Moreover, satisfactory performance has
always been obtained when the cone angle A was slightly greater
than the cone angle B and stable flames which can be maintained
within passageway 16 have only been obtained when the difference
between cone angles A and B is within the range of 10.degree. to
30.degree. positive, that is, the difference of cone angle A is
always greater than cone B by a difference in the range of
10.degree. to 30.degree.. Further, it appears important that the
plasma producing gas as it annularly flows to and around the
central electrode, should be directed by the distributing holes 30
at an angle which produces an annular converging conical stream in
order to maintain a stable plasma flame within the passage 16. A
stream so produced flows through the conical arc space and into
passageway 16 in a straight converging manner. The preferred cone
angle of the stream and therefore, of the distributing holes 30, is
within the range of 19.degree. to 35.degree..
It is also important to note that the included angle between the
recess surface 32 and the nozzle surface 14 should be in the range
of 60.degree. to 120.degree. while the included conical angle A of
the central electrode 12A should be in the range of 80.degree. to
140.degree..
For the sake of simplicity, there has not been illustrated the
shape and configuration of cooling passages which are necessary to
maintain the metal in the nozzle electrode 14 and the central
electrode 12A in usable condition. It should be remembered that a
plasma jet within the passage 16 may have a temperature in the
range of 15,000.degree. to 20,000.degree. C. and that all metal
parts in close proximity to such plasma must be protected by some
form of cooling and the preferred way is water cooling which can be
done in a known manner.
Because the heat flow from the plasma to the parts may be very
high, it is necessary that such parts be made of metal having a
high heat conductivity so that the heat that they receive may be
rapidly dissipated into the coolant. On the other hand, it has been
found that some may react with the plasma forming gas. For
instance, aluminum reacts with nitrogen if that is the plasma
forming gas, and copper may react catalytically with
tetrafluoroethylenes, hereinafter designated as PTFE.
Although the plasma spray device described above may be used for
applying powdered metals, ceramic powder, and various plastic
compositions, to workpieces, the method and apparatus has been
found particularly useful in applying PTFE powder to substrates of
various compositions. In so doing, the workpiece need only be given
ordinary cleaning treatment and not anything extremely special such
as acid cleaning, sand blasting, and the like.
Accordingly, utilizing the method described above and establishing
plasma within the passageway 16 wherein the central electrode has a
conical angle of 120.degree. and the recess inlet 32 has a cone
angle of 90.degree., while the diameter of the passageway 16 is
initially 0.312 inches constricting to 0.296 inches at junction
point 16B, ionizing gas having the composition of N.sub.2 /He ratio
of 6 to 1 is caused to flow through the above device at a rate of
1.5 to 2.0 c.f.m. Through the particle distributing passages 34
there is caused to flow PTFE powder having a generally spherical
shape wherein all of the particles have a major dimension in the
range of 30 to 50 microns and flowing at a rate of 0.01 pounds of
PTFE per c.f.m. of ionizing gas. The workpiece is placed 2 to 3
inches from the exit of the expansion passage 16C. The plasma flame
spraying by such a device will build a coating of PTFE on a
substrate at the rate of 1 mil per minute per 36 square inches of
surface coated. Under these conditions the interior of the nozzle
14 bounding the passage 16 should be coated with a thickness of at
least 0.00015 inches of an alloy very high in nickel, i.e., above
90 percent, whereas the main body of the nozzle 14 would be of
copper. The coating of the interior nozzle 14 can be applied by any
of the well-known processes including electro plating and vapor
deposition.
In carrying out the process described above, the electrical
consumption reduces from 400 amps with a straight longitudinal
passageway 16, to 150 to 200 amps with the constricted passageway
illustrated and claimed herein. Under these conditions, the voltage
will then be in the range of 50 to 100 volts.
PTFE particles having a generally spherical size and having a major
dimension in the range of 10 to 50 microns can be made by oven
baking virgin powder in a known manner.
In selecting the proper combination of materials to be used in the
spray device itself as well as the cone angles to the two
electrodes, one must start with the characteristics of the heat
fusible material to be sprayed and the ionizable gas to be used in
the plasma, bearing in mind that at elevated temperatures chemical
reactions can occur which may not under ordinary high-temperature
conditions react.
The method and apparatus described herein produces coatings of heat
fusible material on substrates which are characterized by their
extreme tenaciousness and performance, while at the same time due
to the utter simplicity of the device and method, being most
economical.
While in accordance with the provisions of the statutes there has
been illustrated and described herein a specific form of the
invention now known, those skilled in the art will understand that
changes may be made in the form of the method or the apparatus
thereof without departing from the spirit of the invention covered
by the claims and that certain features of the invention may some
times be used to advantage without a corresponding use of other
features.
* * * * *