A system (100), apparatus (110), and method (900) for monitored thermal spraying. One or more sensors (610) are used to capture one or more types of measurements (650) to monitor the thermal spraying process. A processor (710) can analyze a waveform (750) of measurements (650), such as electrical measurements (652). The processor (710) can then initiate a response (770) such as a warning (772) or an automatic adjustment (790) that is triggered by an identified operating condition (800).

Provided is an equipment system for producing a piercing-rolling plug to be used for producing a seamless steel tube/pipe, which includes a shotblasting device for applying shotblasting on a surface of the plug, and an arc-spraying device for performing arc-spraying of iron wires on a surface of a base metal of the plug to which the shotblasting is applied, so as to form a film containing oxide and Fe thereon. The arc-spraying device includes plural spraying booths each of which separately forms part of the film in turn in each of sections into which the surface of the base metal of the plug is divided along an axial direction of the plug. The production efficiency of the plug can therefore be maintained at a high level, and steady enhancement of the durability life of the plug can be realized during the piercing-rolling.

Provided is an equipment system for producing a piercing-rolling plug to be used for producing a seamless steel tube/pipe, which includes a shotblasting device for applying shotblasting on a surface of the plug, and an arc-spraying device for performing arc-spraying of iron wires on a surface of a base metal of the plug to which the shotblasting is applied, so as to form a film containing oxide and Fe thereon. The arc-spraying device includes plural spraying booths each of which separately forms part of the film in turn in each of sections into which the surface of the base metal of the plug is divided along an axial direction of the plug. The production efficiency of the plug can therefore be maintained at a high level, and steady enhancement of the durability life of the plug can be realized during the piercing-rolling.

A thermal metal spraying apparatus for applying a metal coating to a target surface. The apparatus provides a cathode, a wire feed stock having a free end, and a wire guide that directs the free end of the wire feedstock to a position for establishing and maintaining a plasma transferred wire arc between the cathode and the free end of the wire feedstock. The wire guide maintains at least three points of contact with the wire feedstock as the wire feedstock is fed through the wire guide.

A thermal metal spraying apparatus for applying a metal coating to a target surface. The apparatus provides a cathode, a wire feed stock having a free end, and a wire guide that directs the free end of the wire feedstock to a position for establishing and maintaining a plasma transferred wire arc between the cathode and the free end of the wire feedstock. The wire guide maintains at least three points of contact with the wire feedstock as the wire feedstock is fed through the wire guide.

This disclosure provides an apparatus, system, and method for thermal spraying a metal cladding on a substrate. The apparatus may include a housing having a first electrode and a second electrode disposed in the housing. The second electrode can be spaced apart from the first electrode. The apparatus includes a first contact tip removably attached to the first electrode and a second contact tip removably attached to the second electrode. The position of the first contact tip and second contact tip is configured to be selectively adjusted on the first electrode and the second electrode to provide a plurality of contact surfaces for a feedstock wire. The apparatus includes a nozzle between the first contact tip and the second contact tip. The first contact tip and the second contact tip are configured to contact and deflect a wire towards the nozzle.

This disclosure provides an apparatus, system, and method for thermal spraying a metal cladding on a substrate. The apparatus may include a housing having a first electrode and a second electrode disposed in the housing. The second electrode can be spaced apart from the first electrode. The apparatus includes a first contact tip removably attached to the first electrode and a second contact tip removably attached to the second electrode. The position of the first contact tip and second contact tip is configured to be selectively adjusted on the first electrode and the second electrode to provide a plurality of contact surfaces for a feedstock wire. The apparatus includes a nozzle between the first contact tip and the second contact tip. The first contact tip and the second contact tip are configured to contact and deflect a wire towards the nozzle.

A method includes depositing a first layer of a first material onto a surface of a chamber component of a processing chamber. The first material comprises a polymer, the polymer having a dielectric strength of at least 40 MV/m. The method further includes depositing a second layer of a second material onto the first layer. The second material comprises a first ceramic material impregnated into the first polymer or a second polymer. The method further includes depositing a third layer. The third layer is of a third material. The third material includes the first ceramic material or a second ceramic material. The third material does not adhere to the first polymer or the second polymer. The third material does adhere to the first ceramic material or the second ceramic material of the second layer.

Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.

Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.