U.S. patent number 3,823,302 [Application Number 05/372,260] was granted by the patent office on 1974-07-09 for apparatus and method for plasma spraying.
This patent grant is currently assigned to Geotel, Inc.. Invention is credited to Erich Muehlberger.
United States Patent |
3,823,302 |
Muehlberger |
July 9, 1974 |
APPARATUS AND METHOD FOR PLASMA SPRAYING
Abstract
An extremely high-powered electrical plasma-jet spray torch is
constructed economically, safely, and in a compact manner, by use
of three coaxial body members held together by longitudinal,
internal bolts. No external housing is necessary, the handle being
screwed directly onto one of the body members. Two removable
electrodes are provided and are separated from each other by a
gas-injector ring of heat-resistant insulating material. The
electrode ends adjacent the gas injector are water-cooled and are
provided with O-ring seals. Powder is injected into the plasma by
use of a rotatable anode adapted to permit selective use of
different types of injection, thus vastly increasing the utility of
the anode. In accordance with the method, supersonic flow is
employed in combination with very high powers, and plural-port
powder injection, to achieve extremely high spray rates.
Inventors: |
Muehlberger; Erich (Costa Mesa,
CA) |
Assignee: |
Geotel, Inc. (Amityville, Long
Island, NY)
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Family
ID: |
26909147 |
Appl.
No.: |
05/372,260 |
Filed: |
June 21, 1973 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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214584 |
Jan 3, 1972 |
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Current U.S.
Class: |
219/121.47;
219/75; 219/121.48; 219/121.5; 313/231.31; 219/76.16;
219/121.49 |
Current CPC
Class: |
B05B
7/168 (20130101); C23C 4/134 (20160101); B05B
7/226 (20130101); C23C 4/137 (20160101); H05H
1/42 (20130101) |
Current International
Class: |
B05B
7/16 (20060101); B05B 7/22 (20060101); C23C
4/12 (20060101); H05H 1/42 (20060101); H05H
1/26 (20060101); B23k 009/00 () |
Field of
Search: |
;219/121P,74,75,76,70
;313/231 ;315/111 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Truhe; J. V.
Assistant Examiner: Peterson; G. R.
Attorney, Agent or Firm: Gausewitz; Richard L.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION:
This is a continuation of application Ser. No. 214,584, now
abandoned filed Jan. 3, 1972, for Apparatus and Method for Plasma
Spraying.
Claims
I claim:
1. A high-power electrical plasma-jet torch, which comprises:
first body means formed of insulating plastic,
said first body means having a large-diameter central passage
therethrough,
second body means formed of metal,
said second body means also having a large-diameter central passage
therethrough,
means to mount said first and second body means adjacent each other
and with said central passages in mutual alignment to thereby form
a continuous passage,
a slug holder formed of metal and inserted into one end of said
continuous passage radially-inwardly of said first body means,
an elongated electrode slug having its base end mounted in said
slug holder at the inner end thereof,
all portions of at least the forward end of said slug being formed
of tungsten,
said slug extending longitudinally of said passage a substantial
distance forwardly from the inner end of said slug holder,
said slug having a diameter smaller than that of said inner end of
said slug holder,
nozzle means formed of metal and inserted into the other
end of said continuous passage radially-inwardly of said second
body means,
the inner end of said nozzle means being spaced longitudinally from
said inner end of said slug holder,
the inner end of said nozzle means encompassing said forward end of
said slug,
a gas-injector ring formed of heat resistant and
electrically-insulating material,
said gas-injector ring being disposed concentrially around said
slug between said inner ends of said slug holder and nozzle
means,
means to maintain a very high-current electric arc at least part of
which is disposed in said nozzle means,
the rear terminus of said arc being at said forward end of said
slug,
means to conduct arc gas to and through said gas-injector ring for
inward flow around said slug and then forwardly through said nozzle
means,
said gas being heated by said arc and discharging from said torch
at a high temperature and velocity, and
means to effect cooling of said nozzle means and of said slug
holder.
2. The invention as claimed in claim 1, in which the nozzle passage
through said nozzle means is supersonic.
3. The invention as claimed in claim 1, in which said
arc-maintaining means is a D.C. source the negative terminal of
which is connected to said slug holder and the positive terminal of
which is connected to said nozzle means.
4. The invention as claimed in claim 1, in which said means to
conduct arc gas to said gas-injector ring includes an annular space
defined between the outer surface of said ring and a part of said
first body means, and further includes circumferentially-spaced
passages extending through said ring and communicating with said
annular space and also with the space between the inner surface of
said ring and the outer surface of said slug.
5. The invention as claimed in claim 1, in which said first body
means comprises two annular components each formed of insulating
plastic, and in which said mounting means mounts said two
components of said first body means adjacent each other and also
adjacent said second body means.
6. The invention as claimed in claim 5, in which said mounting
means comprises a plurality of bolts which extend longitudinally of
the torch through said two components of said first body means and
also through said second body means, and which maintain the same in
closely stacked relationship relative to each other.
7. The invention as claimed in claim 5, in which said slug holder
has a radially-outwardly extending flange which seats between
adjacent portions of said two components of said first body means,
whereby to maintain said slug holder in a predetermined desired
position in said continuous passage.
8. The invention as claimed in claim 1, in which said inner end of
said slug holder has a face which seats against a face at the rear
side of said gas-injector ring, and in which said inner end of said
nozzle means has a face which seats against a face at the forward
side of said gas-injector ring.
9. The invention as claimed in claim 1, in which an O-ring is
provided concentrically around said slug and is seated between said
inner end of said slug holder and a portion of said gas-injector
ring.
10. The invention as claimed in claim 1, in which said nozzle means
defines a relatively large-diameter arc chamber around said forward
end of said slug, and defines a smaller-diameter chamber forwardly
of said forward end of said slug, said smaller-diameter chamber
receiving the forward terminus of said arc when said
arc-maintaining means applies a voltage between said nozzle means
and said slug, and in which said nozzle means further comprises a
relatively small-diameter nozzle passage extending forwardly from
said smaller-diameter chamber.
11. The invention as claimed in claim 10, in which said last-named
nozzle passage is a supersonic passage.
12. The invention as claimed in claim 1, in which said gas-injector
ring is formed of ceramic, and in which said means to conduct arc
gas to and through said gas-injector ring comprises a channel
defined circumferentially around said gas-injector ring between
said ring and an opposed portion of said first body means, and
further comprises passages through said gas-injector ring.
13. The invention as claimed in claim 1, in which said first body
means comprises two annular components each formed of insulating
plastic and stacked relative to each other, and in which said means
to conduct arc gas to and through said gas-injector ring comprises
a tube which extends through the outer one of said two components
and into a passage in the inner one of said two components, and in
which an O-ring is provided around the portion of said tube which
extends into said inner one of said two components.
14. The invention as claimed in claim 1, in which said means to
maintain said electric arc and said means to effect cooling of said
nozzle means and slug holder comprise means to conduct both water
and electricity to said slug holder, means to conduct both water
and electricity to said second body means and around said nozzle
means, and means to conduct water from said second body means
through said first body means to said slug holder.
15. The invention as claimed in claim 1, in which means are
provided to removably mount said nozzle means in said continuous
passage, whereby to facilitate replacement of said nozzle
means.
16. The invention as claimed in claim 1, in which said gas-injector
ring is formed of a ceramic.
17. The invention as claimed in claim 1, in which a handle is
secured by screws to at least one of said first and second body
means, and in which no portion of said handle encompasses either of
said body means.
18. The invention as claimed in claim 1, in which said means to
effect cooling of said nozzle means and slug holder comprises means
to conduct water to said second body means circumferentially around
said nozzle means, an O-ring disposed circumferentially around said
inner end of said nozzle means between said nozzle means and said
first body means, passage means extending through said first body
means to conduct water from said second body means to an annular
recess formed externally in said slug holder, a second O-ring
mounted circumferentially around said inner end of said slug holder
and seated between said inner end and a portion of said first body
means, and means to pass water through said slug holder from said
annular recess therein.
19. The invention as claimed in claim 18, in which said inner end
of said nozzle means is undercut to receive water from said second
body means, whereby to interpose water between said first-mentioned
O-ring and said slug, and in which said inner end of said slug
holder is undercut to receive water from said annular recess in
said slug holder and thereby interpose water between said
second-mentioned O-ring and said slug.
20. The invention as claimed in claim 19, in which a third O-ring
is provided between a rear surface of said gas-injector ring and
said inner end of said slug holder, and third O-ring being cooled
by water contained in said undercut in said slug holder.
21. The invention as claimed in claim 1, in which the means to cool
said nozzle means comprises a plurality of circumferentially-spaced
teeth extending radially-outwardly from said nozzle means and
seated against an interior wall of said second means, said teeth
being disposed radially-outwardly of the portion of said nozzle
means forwardly adjacent said forward end of said slug, means to
conduct water to an annular space formed forwardly of said teeth,
whereby said water flows rearwardly through the gaps between said
teeth, and in which means are provided to conduct water from the
rear portion of said second body means to a drain.
22. Th invention as claimed in claim 21, in which an O-ring is
provided between said nozzle means and said second body means at
the forward portion of said second body means, and in which an
undercut is provided in said nozzle means to interpose water
between said O-ring and the nozzle passage through said nozzle
means.
23. The invention as claimed in claim 1, in which said gas-injector
ring includes gas passages so directed as to effect vortical gas
flow around said slug.
24. The invention as claimed in claim 23, in which there are a
multiplicity of such gas passages, each of small diameter.
25. The invention as claimed in claim 24, in which each of said
passages is inclined forwardly relative to a radial plane
perpendicular to said slug.
26. The invention as claimed in claim 1, in which said gas-injector
ring includes a multiplicity of small-diameter gas flow passages
circumferentially spaced therearound.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of high-pressure, high-power
electrical plasma-jet torches and methods. The invention is
particularly directed to the spray coating of substrates by means
of such torches.
2. Description of Prior Art
Certain apparatus and methods set forth in my copending patent
application Ser. No. 133,126, now U.S. Pat. No. 3,740,522 filed
Apr. 12, 1971, for Plasma Torch, and Electrode Means Therefor, and
in my copending patent application Ser. No. 143,956 now abandoned,
filed May 17, 1971, for Method and Apparatus for Supersonic Plasma
Spray, have been sold and/or in public use for more than one year
prior to filing of the present application; however, the
disclosures of said patent applications are not, per se, prior art
against the present application.
Prior art includes the following U.S. Pat. Nos. 2,768,279;
2,943,182; 3,071,678; 3,114,826; 3,118,046; 3,140,421; 3,145,287;
3,179,782; 3,183,337; 3,197,605; 3,205,338; 3,246,114; 3,272,958
and 3,390,292.
SUMMARY OF THE INVENTION
Three coaxial annular body members, two formed of insulating
material and one of metal, are held in closely nested relationship
by a plurality of internal longitudinal bolts. Into such body
members are inserted coaxial anode and cathode means, the cathode
means including a stick (rod) electrode which extends into an arc
chamber in the anode. The adjacent portions of the anode and
cathode means abut an annular gas injector formed of heat-resistant
insulating material, and which encompasses the stick electrode.
Such adjacent anode and cathode portions are undercut to effect
water cooling of O-ring seals which are provided between the
electrodes and the intermediate body member. No external housing is
required, since a handle means is screwed to the intermediate body
member in enclosing relationship to conduit means which conduct
water, electricity and powder to the anode means.
The anode means is so mounted in the forward body member that it
may rotate about its longitudinal axis. Furthermore, the conduit
means which supplies powder to the anode means is adapted to
register selectively and sealingly with any one of a plurality of
differently-constructed ports, depending on the rotated position of
the anode means. Thus, the powder-injection characteristics may be
quickly and economically altered as desired.
Extremely high spray rates are achieved by simultaneously employing
very high electrical powers, supersonic gas flow, and plural-port
powder injection. The present apparatus and method are thus such
that a small, safe, compact, high-powered plasma torch achieves
surprisingly high spray rates relative to the spray-coating of a
substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view illustrating an electrical
plasma-jet spray torch constructed in accordance with the present
invention;
FIG. 2 is a sectional view taken on line 2--2 of FIG. 1;
FIG. 3 is a section taken on line 3--3 of FIG. 2;
FIG. 4 is an enlarged fragmentary sectional view showing a
lower-right portion of the torch of FIG. 1, and also illustrating
in dashed lines various alternative positions for the powder
port;
FIG. 5 is a transverse sectional view on line 5--5 of FIG. 1;
FIG. 6 is a transverse sectional view on line 6--6 of FIG. 1;
and
FIG. 7 is a transverse sectional view illustrating schematically an
embodiment wherein a plurality of powder sources are employed to
inject powder into the torch.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, the torch body is illustrated to
comprise three annular body members 10, 11 and 12 which are mounted
in closely nested relationship relative to each other. The rear
body member, numbered 10, is formed of a suitable insulating
plastic such as a phenolic. The intermediate body member 11 is also
formed of insulating plastic but preferably one which is much
stronger, such as a fiber glass-resin composition. Front body
member 12 is formed of metal, such as brass.
Each of the annular body members defines an opening therethrough,
and the three such openings combine to produce an opening or
passage through the torch. Into such torch opening or passage are
inserted the anode and cathode means, as described below.
The annular body members 10-12 are maintained in assembled
relationship, despite the very high pressure contained therein, by
means of three bolts 13-15 (FIGS. 1 and 2) which are oriented
longitudinally to the common axis of the body members and are
circumferentially spaced 120.degree. from each other. The bolts
extend interiorly of the body members, instead of through external
flanges or connectors, thereby greatly improving the compactness of
the torch.
The head of each bolt 13-15 is recessed into a cylindrical cavity
in the forward surface of front body member 12. The threaded rear
end of each bolt is threaded into a nut 16 (FIG. 1) which is
mounted in a recess in the rear member 10. An insulating plug 17 is
cemented into the recess in member 10 to conceal the rear end of
each bolt and to prevent the operator from making electrical
contact therewith.
It is emphasized that all portions of the torch rearwardly of the
metallic front body member 12 are insulating, except for the
connection to the cathode means described below. This relationship
makes the present apparatus relatively safe to operate.
As shown in FIGS. 1 and 3, the body members 10-12 receive in
snug-fitting relationship an anode means 18 and a cathode means 19,
the latter having a stick (rod) electrode portion 21 which extends
coaxially into an arc chamber 22 in the anode means.
A gas-injector ring 23, formed of a heat-resistant insulating
ceramic such as boron nitride, aluminum oxide, zirconium oxide,
etc., is mounted between the adjacent or inner end portions of the
anode means and the cathode means and in radially-outwardly spaced
concentric relationship to the stick electrode portion 21. More
specifically, the cylindrical inner surface of gas-injector ring 23
is flush with the cylindrical surface of the side wall of arc
chamber 22, so that the gas-injector ring and the anode means
cooperate to define a gas-vortex chamber 22a around the stick
electrode portion.
Arc gas is introduced into such gas-vortex chamber 22a through a
multiplicity of small-diameter gas-inlet passages 24 (FIGS. 1, 3
and 5) which are drilled through the gas-injector ring 23. The
illustrated passages 24 are, in the illustrated embodiment,
tangentially oriented relative to the gas-vortex chamber 22a and,
furthermore, incline somewhat forwardly relative to a vertical
plane which is perpendicular to the axis of the apparatus. In some
instances, however, other types of gas injection may be employed,
for example injection which is not adapted to effect vortical flow
in the chamber around the stick electrode.
It is an important advantage of the present torch that the manner
of arc gas injection may be readily changed, merely by substituting
one ring 23 for another. The ring 23 also produces other important
advantages, including (a) permitting the vortex chamber 22a to be
small in diameter, and (b) effectively insulating the anode and
cathode from each other.
Gas-injector ring 23 has a rectangular cross section except at the
exterior surface thereof, which is provided with an annular groove
26 communicating with the various gas-inlet passages 24. The ring
23 is seated in a recess or counterbore which is formed in the
forward side of intermediate body member 11. The wall of such
recess or counterbore is undercut, at the region radially-outwardly
of groove 26, to provide an annular manifold chamber 27 into which
arc gas is introduced through a passage 28 (FIG. 3). Passage 28
communicates with a recess in intermediate body 11, and into which
a tube 29 is sealingly inserted (there being an O-ring 31). Tube 29
is soldered to a fitting 32 adapted to be connected to a gas source
which is schematically represented at 33.
It is emphasized that, in accordance with the present apparatus and
method, a very large amount of power is "packaged" within a very
small space, with consequent enormous generation of heat. For
example, in a torch wherein the arc chamber 22 is only about
two-thirds of an inch in diameter, the power input may be between
80 kilowatts and 100 kilowatts. The heat-resistant gas-injector
ring 23, particularly since it is spaced rearwardly from the arcing
tip of the electrode 21, is able to withstand the resulting
extremely high temperatures. However, means are provided to cool
the seals which prevent escape of gas from manifold chamber 27
except through the gas-inlet passages 24.
The inner end of anode means 18 has a radial flange the rear radial
surface of which is abutted against the radial forward surface of
gas-injector ring 23. The flange extends outwardly to a cylindrical
element 34 the exterior surface of which abuts an O-ring 36 which
is mounted in a groove formed in the interior wall of intermediate
body 11. Furthermore, an undercut is formed between the element 34
and the main body of the rear portion of anode means 18, into which
water flows to thereby maintain O-ring 36 sufficiently cool that it
will not deteriorate.
In simiar manner, the forward end of the stick-holder or
slug-holder portion (described hereinafter) of cathode means 19 is
provided with a radial flange and with a cylindrical element 37,
the latter contacting an O-ring 38 which is seated in the
intermediate body. The resulting undercut receives water which
maintains the O-ring 38 relatively cool. In addition, an O-ring 39
is mounted in the radial forward surface of the slug holder, in
contact with the radial rear wall of the gas-injector ring 23,
being cooled by water present in the undercut in the cathode
means.
There will next be described the remainder of the cooling means
which maintain the anode and cathode means sufficiently cool that
they will not melt or deteriorate excessively, despite the great
heat which is generated by the electric arc. Water from a suitable
source 41 (FIG. 1) is caused to flow rapidly through a
large-diameter conduit 42 and thence into a right-angle fitting 43
the upper end of which is brazed into a recess in front body 12.
The fitting communicates with an annular groove 44 formed in the
front body 12. From such groove 44, the water is forced rearwardly
through a large number of saw cuts or notches 46 (FIG. 6) which is
defined by teeth 47 extending outwardly from anode means 18 at the
region around arc chamber 22. The teeth 47 are in surface
engagement with an interior cylindrical surface 48 of the front
body 12, so that the water is not merely caused to flow around the
saw cuts or notches 46 but instead is forced rapidly therethrough
in highly efficient cooling relationship to the anode means.
The interior surface 48 is formed on a neck portion of the front
body 12, such neck portion extending rearwardly into a large
counterbore in intermediate body 11. An O-ring 49 is provided to
prevent leakage of water out of such counterbore.
The rear end of the neck portion of front body 12 is spaced
forwardly from the opposed radial surface of intermediate body 11
at the indicated counterbore, whereby to form an annular chamber 50
into which the water flows after leaving the saw cuts or notches
46. It is emphasized that the water entering the chamber 50
impinges against the above-described cylindrical element 34 to aid
in cooling the O-ring 36 adjacent thereto.
From chamber 50, the water flows rearwardly through a large number
of circumferentially-spaced longitudinal bores or passages 51 in
intermediate body 11 (FIG. 5), such bores having rear portions
which incline inwardly and rearwardly to the chamber 52 which is
defined in intermediate body 11 around cathode means 19. The
chamber 52 communicates with a plurality (for example, six) of
passages 53 which are formed through the cathode means 19 and which
communicate with a central passage 54 therein and thus with a
fitting 56 leading to a suitable drain 57.
An O-ring 58 is provided around the cathode means 19 to prevent
leakage of water from chamber 52. An additional O-ring, numbered
59, is formed around the front portion of the anode means 18
between a cylindrical external surface thereof and an interior
cylindrical surface of the front body 12, forwardly of annular
groove 44. Heating of the last-mentioned O-ring 59 is prevented by
water present in an undercut region 60 of the anode means, such
region being located radially-inwardly of a cylindrical portion 61
of the anode means and which abuts the O-ring 59.
Anode means 18 is a single element made of copper, and which is
machined or otherwise formed to contain the various cooling
portions described above. The anode means also contains the arc
chamber 22 as described, which arc chamber 22 communicates
coaxially with a smaller-sized arc chamber or counterbore 62
located forwardly of the rounded tip of the cathode stick or slug
21. The forward regions of the arc chamber 22 and of the smaller
arc chamber 62 are generally rounded or spherical.
The smaller arc chamber 62 communicates coaxially with a nozzle
passage 63 having a cylindrical rear portion and a somewhat flared
or conical forward portion. The illustrated nozzle passage is of
the supersonic type, as is greatly preferred for reasons stated
hereinafter, but it may also be subsonic if desired for certain
applications. Nozzle passage 63 will not be described in detail
since counterparts thereof are set forth in my copending patent
application Ser. No. 143,956 now abandoned, cited above.
The present spray torch is of the non-transferred arc variety,
wherein the entire arc is contained within the torch. Thus, a D.C.
power source 64 (FIG. 1) has the positive terminal thereof
connected to conduit 42 (which is formed of copper) to thereby
supply D.C. power of positive polarity to the fitting 43 and thus
to the front body 12 and to the anode means 18 in contact
therewith. The negative terminal of power source 64 is connected to
fitting 56 and thus to the cathode means 19. An electric arc is
thus maintained between the tip of the cathode means and the wall
of the arc chamber 62.
Because gas is introduced at high pressure from source 33 (FIG. 3)
through the passage described above, the gas pressure in chambers
22 and 62 is high (for example, 120 psi gauge when the electric arc
is present). This high pressure cooperates with the high electric
power contained in the torch, and with the characteristics of
nozzle passage 63, in such manner that the flow through the nozzle
passage is caused to be supersonic, for example between Mach 1 and
Mach 3 (preferably about Mach 2 when spraying is being effected in
the atmosphere, as distinguished from being effected in a vacuum
chamber).
The present torch may also be employed for cutting purposes, for
example by causing the positive terminal of D.C. power source 64 to
connect to an electrically conductive workpiece (such as a steel
plate to be cut) instead of to the conduit 42. For cutting
purposes, the nozzle passage 63 is preferably shortened, and the
electric arc extends clear through the nozzle passage from the
stick electrode 21 to the workpiece.
As previously indicated, the cathode means 19 comprises (in
addition to the thoriated tungsten slug, stick or rod 21) a
slug-holder or stick-holder 66 having a radial flange 67. Such
flange is seated between the bottom of a recess in rear body 10 and
the rear end of a neck 88 on intermediate body 11. The slug holder
66 is preferably formed of copper.
Referring next to FIGS. 1, 2 and 6 in particular, the torch further
comprises handle means which are screwed directly to the torch body
by means of the screws 70. The screws project into inserts in the
intermediate body 11, which (being formed of fiber glass) is very
strong. Screws 70 project respectively through the upper ends of
first and second handle portions 71 and 72 which are mirror images
of each other and abut at the central plane of the torch. Portions
71 and 72 are secured together by bolts 73 and 74 shown in FIG.
1.
The handle portions 71 and 72 have grooves therein which cooperate
to form passages through which the above-described conduit 42
passes, as does an additional tube or conduit 76 adapted to supply
spray powder to nozzle passage 63 as described below. Both the
conduit 42 and the conduit 76 extend upwardly through the handle
and then bend forwardly to a position in advance of the handle,
whereupon they bend upwardly into forward body 12 as shown in FIG.
1.
Powder tube 76 is supplied by a source 75 (FIG. 1) with spray
powder entrained in gas. Such a source is shown in U.S. Pat. No.
3,517,861.
DESCRIPTION OF THE SELECTIVE-PORT POWDER SUPPLY MEANS
The upper end of powder conduit 76 projects slidably through a
corresponding radial bore in the lower region of front body member
12. Furthermore, as best shown in FIG. 4, the extreme upper end of
the powder conduit or tube 76 is beveled at 78 to abut the conical
wall of a recess 79 formed in anode means 18. A cross-member or
fitting 80 (FIG. 2) is rigidly secured to the powder tube or
conduit 76 (as by brazing), and is fastened by screws 81 (FIG. 2)
to the front body 12.
Loosening of the screws 81 permits the operator to shift the upper
end of powder tube 76 downwardly and out of the recess 79 (FIG. 4),
thereby permitting rotation of the anode means 18 as described
below. Correspondingly, tightening of the screws 81 forces the
beveled upper end of tube 76 into recess 79 and effects a seal with
the wall of such recess, so that all gas and powder which flow
upwardly through the tube 76 pass into the nozzle passage 63.
Anode means 18 is provided with a plurality, for example eight in
the illustration, of such recesses 79 (FIG. 4), in
circumferentially-spaced relationship. Each recess 79 communicates
with a port or passage which extends inwardly to the nozzle passage
63. The various ports or passages are numbered 82-89 in FIG. 2, and
each has at least one characteristic different from that of all the
others. Thus, for example, the passages may have different
diameters, different inclinations, etc.
As an example, the passage 85 (FIG. 2) is shown as being
tangentially related to the nozzle passage, the relationship being
such that the powder is introduced in a clockwise manner as viewed
from the front of the torch. This is opposite to the direction of
introduction of arc gas through injector ring 23, this being
counterclockwise as shown in FIG. 5.
Referring to FIG. 4, the passages 82a and 82b correspond to passage
82 except that they are inclined at different angles relative to a
plane which is perpendicular to the nozzle passage 63 and contains
the powder tube 76. It is pointed out that the three passages 82,
82a and 82b (FIG. 4) are not present in the same torch (there
preferably being only one port 82, etc., which communicates with
tube 76 at any one time). The passages 82a and 82b are illustrated
herein as alternative angles of powder introduction. Various angles
and types of powder introduction are described in my copending
application Ser. No. 143,956 now abandoned, cited above.
To cause a selected one of passages 82-89 to register with powder
conduit 76, the upper end of such conduit is lowered by loosening
the screws 81 (FIG. 2) as described above. Thereafter, a front
retainer ring 92 (which normally locks the anode means 18 in
position) is removed from the front of the torch by removing
mounting screws 93 (FIG. 3) therefor. After the front ring is
removed, a threaded tool is inserted into an internally-threaded
bore 94 (FIG. 1) in the forward face of the anode means 18.
The threaded relationship between the tool and the threads in bore
94 permits the operator to pull the entire anode means 18 forwardly
for a fraction of an inch, until there is no longer any engagement
with an indexing pin 96 (FIG. 1) which is permanently and fixedly
mounted in the forward face of front body 12 in parallel
relationship to the axis of the torch. The pin 96 is selectively
received in any one of eight circumferentially-spaced bores 97
which are provided in a flange 98 in anode means 18. Each bore 97
corresponds in position to one of the conical recesses 79 described
relative to FIG. 4. The flange 98 seats in a counterbore in the
face of front body 12.
Since the indexing pin 96 is no longer inserted in one of the bores
97 after the anode means 18 is pulled forwardly as stated above,
the operator may rotate the anode in order to cause the desired one
of passages 82-89 to register with the upper end of powder conduit
76. Thereafter, the anode 18 is pushed rearwardly until indexing
pin 96 is again inserted in one of the bores 97, following which
the front ring 92 is mounted in position by means of screws 93, and
following which the screws 81 (FIG. 2) are tightened to elevate the
powder tube 76 and effect a seal at bevel 78 (FIG. 4) as stated
above.
The described rotation of the anode 18 permits a single anode to
have a much greater utility than in the prior art, so that various
types of powders, various settings of the torch, etc., may be
employed with a single anode as necessary in order to achieve
maximum spray rates.
DESCRIPTION OF THE METHOD, EMBODIMENT OF FIG. 7
Th method which will next be described, in connection with FIG. 7,
relates to the discovery that the combination of supersonic plasma
flow, simultaneous plural-port injection of spray powder, and very
high arc power produces spray rates which are surprisingly high. It
is emphasized, however, that the arc power must be related to the
size of the torch, since the larger torches normally generate arc
powers much higher than do the smaller torches.
The torch and method described in my copending patent application
Ser. No. 143,956 now abandoned, cited above, discloses supersonic
flow but does not disclose simultaneous plural-port powder
injection. such prior-art U.S. Pats. Nos. as 3,144,826; 3,183,337;
and 3,197,605 teach plural-port powder injection, but only at
subsonic flows and relatively low arc powers. U.S. Pats. Nos.
3,179,782 and 3,246,114 purport to teach supersonic flow, and
appear ambiguous relative to whether or not there are plural powder
ports. It has now been ascertained that if the arc power is
extremely high compared to the size of the torch, if plural-port
powder injection is employed, and if supersonic flow is employed,
then the spray rates increase extremely rapidly.
The method will be described in connection with the present torch,
which has (as mentioned above) an arc chamber diameter of about 2/3
inch (chamber 22). The torch has a nozzle passage diameter of 0.234
inch at the smallest portion thereof, and a nozzle passage length
of 0.812 inch.
For a torch of the indicated size, the arc power is in excess of 50
kilowatts, and is preferably in the range of 80 kilowatts to 100
kilowatts. As one illustrative condition, the arc current is 900
amperes and the arc voltage 90 volts.
The pressure of the arc gas (for example, argon) introduced from
source 33 (FIG. 3) is in excess of 50 psi gauge, which produces in
arc chamber 22 a gas pressure of 120 psi gauge after the arc is
initiated. The combination of the high gas pressure and the high
arc power combine with the characteristics of the supersonic nozzle
passage 63 to create a supersonic flow through the nozzle and out
the torch. The velocity of the plasma emanating from the torch may
be about 10,000 feet per second when spraying occurs in the
atmosphere. Stated otherwise, the plasma emanating from the torch
is in the range of Mach 1 to Mach 3, being preferably about Mach 2
(when spraying is in the atmosphere as distinguished from in a
vacuum chamber).
By plural-port powder injection it is meant that separate powder
sources are employed simultaneously to feed powder and gas through
separate conduits to the nozzle passage 63, as described below
relative to FIG. 7. It is not preferred to use a single powder
source which feeds powder and gas to a plurality of ports.
Referring to FIG. 7, there is schematically represented a powder
source 101 and a powder source 102 which are connected,
respectively, to the torch by means of powder tubes 103 and 104.
Such sources 101 and 102 combine with powder from the first source
75 and which is connected through the tube 76 as described relative
to FIGS. 1 and 4.
The powder tubes 103, 104 and 76 communicate, respectively, with
powder ports 106, 107 and 82a which is provided in the anode means
18a.
In the present example, all of the ports 106, 107 and 82a
correspond to each other in diameter, angle, etc., and all are
constructed as shown in FIG. 4 relative to port 82. It is to be
understood, however, that different longitudinal or circumferential
positionings may be employed, as well as different angular
relationships, etc.
In the present example, and with the torch of the size described
above, each port 106, 107 and 82a has a diameter (for example) of
1/16 inch. The rate of gas flow from each source 101, 102 and 75 is
50 scfh. The spray coating is thus deposited on a substrate (not
shown) at a rate of, for example, 40 pounds per hour.
Except as specifically stated above, the torch of FIG. 7 is
identical to the one previously described in detail relative to
FIGS. 1-6, inclusive.
It is pointed out that the anode means 18 may also be regarded as a
"nozzle means," since it has a nozzle passage 63 therethrough.
Also, the cathode means 19 may be regarded as a "rear electrode
means." The front end of slug holder 66 is a "shoulder portion"
which extends radially outwardly from stick electrode 21.
The foregoing detailed description is to be clearly understood as
given by way of illustration and example only, the spirit and scope
of this invention being limited solely by the appended claims.
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