A method and coating system are provided that use a temperature controlled gas flow to smooth a surface of a ceramic, like a thermal barrier coating (TBC). Thermal spray coating unit coats a ceramic on a surface. The thermal spray coating unit creates a flow of ceramic material towards the surface. A layer of at least partially molten ceramic material on the surface is smoothed by transmitting a flow of temperature controlled gas across the at least partially molten ceramic material on the surface after the thermal spray coating of the ceramic on the surface. The solidified ceramic has a smoother surface that requires much less polishing to attain a desired surface roughness.

A thermal spray cabin comprising a table to hold a part to be coated and a robot with a robot body and an arm, a spray gun mounted on the arm of the robot, a ventilation system comprising an air inlet and a suction hood designed to create a gas flow with a main stream from the air inlet to the suction hood thereby passing the table in an operating state of the thermal spray cabin. The air inlet, the table, the robot and the suction hood are arranged in such a way, that the robot body is positioned outside the main stream of the gas flow in the operating state.

A thermal spray cabin comprising a table to hold a part to be coated and a robot with a robot body and an arm, a spray gun mounted on the arm of the robot, a ventilation system comprising an air inlet and a suction hood designed to create a gas flow with a main stream from the air inlet to the suction hood thereby passing the table in an operating state of the thermal spray cabin. The air inlet, the table, the robot and the suction hood are arranged in such a way, that the robot body is positioned outside the main stream of the gas flow in the operating state.

The invention relates to the nozzle construction for thermal spraying by means of a suspension, in which particles are contained, or a precursor solution, by means of which particles or precursor solution a layer is formed on a substrate, and which suspension or precursor solution is fed into a burner chamber or into a plasma torch, in which heating and acceleration of the particles is achieved, wherein a connection point for feeding the suspension or the precursor solution, a holder, and a nozzle insert are present. The nozzle insert has, with a tubular element arranged in the direction of the burner chamber or perpendicularly in HVOF flame or plasma torch and with an end face arranged opposite the burner chamber, a flange-shaped expanded section, which lies against a seat formed in the holder in the installed state. The contours of the flange-shaped expanded section and of the seat are complementary to each other such that the surfaces of the flange-shaped expanded section and of the seat are in direct contact with each other and an end stop and a seal are formed in this region.

PROBLEM: To provide a large device and a method which is advantageous for forming a large-area amorphous film. SOLUTION: A device of the invention sprays a flame including a particulate material with a spraying machine toward a substrate, melts the material with the flame, and cools the material and flame by cooling gas before they reach the substrate to form an amorphous film. The spraying machine has particulate material spraying ports and flame spraying ports such that the flame including the material has an oblong cross section. Inert gas spraying ports are successively placed on both sides across the ports of the material and flame. Mist spraying ports are successively placed on both sides across the ports for the material, flame and inert gas. A skirt is attached/detached depending on a combustion gas or a film width to restrain film width narrowing and increase of film thickness deviation.

PROBLEM: To provide a large device and a method which is advantageous for forming a large-area amorphous film. SOLUTION: A device of the invention sprays a flame including a particulate material with a spraying machine toward a substrate, melts the material with the flame, and cools the material and flame by cooling gas before they reach the substrate to form an amorphous film. The spraying machine has particulate material spraying ports and flame spraying ports such that the flame including the material has an oblong cross section. Inert gas spraying ports are successively placed on both sides across the ports of the material and flame. Mist spraying ports are successively placed on both sides across the ports for the material, flame and inert gas. A skirt is attached/detached depending on a combustion gas or a film width to restrain film width narrowing and increase of film thickness deviation.

An example system includes at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process associated with a plurality of process attributes. The example system includes a computing device including an acoustic data signal module and a control module. The acoustic data signal processing module may transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum. The control module may determine a process attribute of the plurality of process attributes that deviates from a predetermined operating range by identifying at least one characteristic of the frequency-domain spectrum, selecting at least one component of the thermal spray system based on the process attribute, and controlling the thermal spray system to adjust the process attribute toward the predetermined operating range by sending a control signal to the at least one component.

An example system includes at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process associated with a plurality of process attributes. The example system includes a computing device including an acoustic data signal module and a control module. The acoustic data signal processing module may transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum. The control module may determine a process attribute of the plurality of process attributes that deviates from a predetermined operating range by identifying at least one characteristic of the frequency-domain spectrum, selecting at least one component of the thermal spray system based on the process attribute, and controlling the thermal spray system to adjust the process attribute toward the predetermined operating range by sending a control signal to the at least one component.

A spray nozzle has a body having a flow passage. At least along a portion of the flow passage the body has a depth-wise compositional variation having: a cemented carbide first region; and a cemented carbide second region closer to the flow passage than the first region and having a higher boron content than a boron content, if any, of the first region.

Processing apparatus for processing a workpiece surface in form of an internal coating of cylinder bores which are arranged in a row. The apparatus includes a shield unit which is provided to separate from one anotherat least during operationa part region of the workpiece surface provided for the processing and an adjacently arranged part region of the workpiece surface, whereby the shield unit has at least one blocking nozzle which is provided to generate a fluid flow for separating the at least two part regions, wherein the blocking nozzle is positioned such that the fluid flow flows along the workpiece surface and the blocking nozzle is directed to the part region between two cylinder bores.