A thermal spraying method for coating an inner surface of a cylinder of an internal combustion engine or a piston engine. The method includes applying a thermal spray layer to the inner surface of the cylinder via a spray jet which is emitted by a spray torch and which includes a spray material, optically monitoring, via an optical sensor device, surroundings of the spray jet as defined by a space outside the spray jet, and assuming a coating process to be defective if the optical sensor device detects one or more particles of the spray material supplied to the spray torch in the surroundings monitored outside the spray jet and a parameter of the one or more particles exceeds a defined threshold.

The plasma spraying apparatus includes a cathode, a first gas nozzle defining a first gas path between the cathode and itself, a second gas nozzle defining a second gas path between the first gas nozzle and itself, and a third gas nozzle disposed between the first and second gas nozzles to define a third gas path between the first and second gas paths. A wire is disposed at a distal end thereof in front of a nozzle opening of the second gas nozzle. A first gas sprayed through the first gas nozzle is turned into plasma flame, which melts the wire into droplets, and the droplets are sprayed onto a target by a second gas sprayed through the second gas nozzle. The third gas absorbs heat from the plasma flame to thereby turn into a high-temperature gas flow externally of the plasma flame.

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).

A method of applying a corrosion-resistant coating to a fastener that includes preheating an area of the fastener to be coated to elevate a temperature of the area and spraying the preheated area of the fastener with a molten or semi-molten metal. In one embodiment, a corrosion-resistant coating applicator includes a support structure, a rotatable slotted fastener conveyer supported by the support structure, a feeder configured to feed fasteners to the rotatable slotted fastener conveyer, a fastener aligner configured to make head portions of the fasteners aligned with each other, a heater configured to heat head portions of the fasteners as the fasteners are being conveyed by the slotted fastener conveyer, and a sprayer configured to apply a corrosion-resistant coating to the heated head portions of the fasteners being conveyed by the slotted fastener conveyer. The present disclosure also provides corrosion-resistant coated fasteners made using the coating methods and/or coating apparatus.

A transferred-arc plasma torch comprising a sheath cooled using a cooling fluid and an electrode inserted in said sheath. The electrode is made of a consumable material and the torch comprises means to supply the electrode with this material so as to offset its erosion.

A composite wire for use with a wire arc spray system and related methods. The composite wire can include: a low melting point material at a core region thereof and a cladding including a metal surrounding the core region, the low metal point material having a melting point less than that of the metal, wherein the low melting point material includes a polymer in the form of a powder having particles having a size of from approximately 1 nanometer to approximately 100 nanometers.

An additive manufacturing system includes an additive manufacturing tool configured to supply a plurality of droplets to a part, a temperature control device configured to control a temperature of the part, and a controller configured to control the composition, formation, and application of each droplet to the plurality of droplets to the part independent from control of the temperature. of the part via the temperature control device. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material.

A wire arc spray system (100) includes a plurality of arc spray subsystems (130) mounted to a movable carriage (120) on an x-y robot (110). Each arc spray subsystem includes a wire drive (132) that provides wire (133, 134) to a spray head (138) through a pair of lead cables (136). The spray heads are mounted for circular motion, such that the molten spray is applied to an underlying substrate in a swirling pattern. In one embodiment, the spray heads are mounted to a distal end of a rod (164) that extends through a swivel ball joint (166) and engages an eccentric link (162) fixed to a motor (160). The system applies an overlapping pattern of molten spray to provide excellent non-skid and adhesion properties. The system is particularly suited to spray coating with a wire comprising a hollow metallic portion and a core having ceramic particles.

The disclosure presents systems and methods for refurbishing an artificial gas lift plunger of a gas well system. According to the embodiments described herein, the systems and methods can remove a portion of a plunger body of a cylindrical artificial gas lift plunger of a gas well system. The removed portion(s) of the plunger body can cause the plunger body to be radially symmetric with a uniform body thickness along the length of the plunger body. Further, body material can be deposited onto the plunger body, substantially adhering to the plunger body and forming an increased thickness of the plunger body. Moreover, body material can be removed from the plunger body to cause a substantially uniform thickness of the plunger body.

The present invention relates to the field of surface alloy pipe manufacturing, and provides a process and spraying equipment for arc spraying carbon steel pipes. The process includes the following steps: S1: installing a raw metal wire on a wire feeder, adjusting the wire feeding voltage according to the required thickness of spraying, and adjusting the spraying current according to the material of the raw metal wire; S2: spraying an inner and outer walls of the pipe through an inner wall spray gun and an outer wall spray gun; S3: after the pipe being sprayed, cooling it naturally to room temperature; S4: putting the cooled pipe into a heating furnace, adjusting the heating temperature according to the required surface alloy thickness, and cooling it in the furnace or natural cooling outside the furnace after the insulation is completed; meanwhile, a surface alloy layer is formed on the inner and/or outer wall of the carbon steel pipe; S5: after the pipe being cooled to room temperature, using a medium frequency heat treatment equipment to heat-treat the pipe through the heat treatment process. The present invention solves the problems that the existing arc spray equipment cannot spray the inner wall of the pipe, and the spray coating has poor bonding force with the pipe body and is easy to fall off. It greatly improves the wear resistance, high temperature resistance and anti-corrosion performance of the inner and outer wall surfaces of the pipe, and increases the pipe life.