An atomizing spray nozzle device includes an atomizing zone housing that receives different phases of materials used to form a coating. The atomizing zone housing mixes the different phases of the materials into a two-phase mixture of ceramic-liquid droplets in a carrier gas. The device also includes a plenum housing fluidly coupled with the atomizing housing and extending from the atomizing housing to a delivery end. The plenum housing includes an interior plenum that receives the two-phase mixture of ceramic-liquid droplets in the carrier gas from the atomizing zone housing. The device also includes one or more delivery nozzles fluidly coupled with the plenum chamber. The delivery nozzles provide outlets from which the two-phase mixture of ceramic-liquid droplets in the carrier gas is delivered onto one or more surfaces of a target object as the coating on the target object.

A method of controlling application of material onto a substrate is provided. The method includes ejecting an ultraviolet (UV) curable material through a plurality of micro-applicators in the form of atomized droplets. At least one UV light source is positioned adjacent to the plurality of micro-applicators and the atomized droplets are irradiated with UV light by the at least one UV light source and curing of the atomized droplets is initiated. The atomized droplets are deposited onto a surface of the substrate and a UV cured coating on the surface is formed thereon. The UV curable material may include a photolatent base catalyst such that the atomized droplets deposited onto the surface continue to cure after being irradiated with the at least one UV light source. The at least one UV light source can include a UV light ring, a UV light emitting diode, and the like.

An atomizer for applying a coating includes a nozzle plate, an actuator, and an acoustic focusing device. The nozzle plate defines at least one aperture. The actuator is configured to oscillate to form pressure waves within a fluid to eject the fluid from the nozzle plate. The acoustic focusing device focuses the pressure waves toward the apertures.

A nozzle for an atomizer includes a plate, a piezoelectric actuator, a body, and a connector. The plate defines an aperture. The actuator is configured to oscillate the plate. The body supports the plate. The connector is configured to reversibly mount the body to the atomizer in a first orientation and in a second orientation. In the first orientation, fluid exits the nozzle along a first axial direction through the aperture. In the second orientation, fluid exits the nozzle along an opposite axial direction through the aperture.

A method of controlling application of material onto a substrate includes ejecting atomized droplets from an array of micro-applicators while the array of micro-applicators cyclically moves about at least one axis. The atomized droplets from each of the plurality of micro-applicators overlap with atomized droplets from adjacent micro-applicators and a diffuse overlap of deposited atomized droplets from adjacent micro-applicators is provided on a surface of the substrate. The array of micro-applicators cyclically rotates back and forth around the at least one axis and/or moves back and forth parallel to the at least one axis. For example, the at least one axis can be a central axis of the array of micro-applicators, a length axis of the array of micro-applicators, a width axis of the array of micro-applicators, and the like. Also, the array of micro-applicators can be part of an ultrasonic material applicator used to paint vehicles.

A method of controlling application of at least one material to a substrate is provided. The method includes configuring at least one array having a plurality of micro-applicators such that a subset of the micro-applicators is individually addressable to apply the at least one material to the substrate. Individually addressing the subset of micro-applicators provides control of a pattern width of a coating applied to a substrate, control of a flow rate of the material applied to the substrate, control of an angle of application of the material to the substrate, control of which and how many materials are applied to the substrate, and combinations thereof.

An apparatus for applying a coating to a substrate includes a base, an applicator, and a quick-connect connector. The base includes a fluid conduit. The applicator includes at least one actuator and an array of nozzle plates. Each nozzle plate defines at least one aperture. The at least one actuator is configured to oscillate the nozzle plates to eject fluid from the apertures. The quick-connect connector couples the fluid conduit to the applicator for fluid communication therebetween.

A film forming method of forming a film by accelerating powder of a material with gas and spraying and depositing the powder onto a surface of a substrate with the powder being kept in a solid state includes: a substrate film forming step of forming a film. The film forming step includes jetting out the powder and inert gas from a nozzle towards the substrate, causing inside of the chamber to be under positive pressure by the inert gas, and depositing the powder on the surface of the substrate.

A system is disclosed for use in manufacturing a composite structure. The system may include a support configured to move in a plurality of directions during manufacturing of the composite structure, and a head coupled to the support. The head may have a housing that is configured to receive a liquid matrix and at least one continuous fiber and configured to discharge a tubular structure. The head may also have a nozzle operatively connected to the housing and configured to deposit a material layer onto a surface of the tubular structure as the tubular structure is discharging from the housing, and a squeegee associated with the nozzle and configured to wipe over the material layer. The head may further have a first cure enhancer operatively connected to the housing and configured to cure the liquid matrix in the tubular structure during discharge, and a second cure enhancer configured to cure the material layer deposited by the nozzle.

Systems and methods that provide or restore a coating to a component are provided. The systems and methods utilized an atomizing spray device. A gas and a slurry that comprises fluid and ceramic particles are supplied to the atomizing spray device. The slurry and gas are discharged from the spray device to form two-phase droplets. The fluid within the droplets evaporates to prevent the fluid from becoming part of the coating as the droplets traverse through the air and prior to impacting the surface of the component.