A method for producing a thermal spray powder includes: a preparing step of preparing a powder mixture containing a first particle made from zirconia-based ceramic containing a first additive agent and a second particle made from zirconia-based ceramic containing a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm; and a secondary-particle producing step of producing a plurality of secondary particles each of which includes the first particle and the second particle sintered with each other.

The invention relates to a method for coating cavity walls, in particular cylinder bores of engine blocks. In the method, a coating is applied to a cavity wall using a coating lance. In addition, a cavity diameter is measured using a measuring apparatus. According to the invention, the method is characterized in that at least a plurality of diameter values of a first cavity are measured at different heights of the first cavity using the measuring apparatus, and in that a coating of variable thickness is applied to a wall of the first or a second cavity using the coaling lance, the thickness of said coating of variable thickness being dependent on the determined diameter values. The invention additionally describes a corresponding coating system.

A powder feeder according to one aspect of the present disclosure is a powder feeding device that feeds powder from a feeder to a nozzle. The powder feeding device includes a cartridge configured to store the powder in an airtight condition, and includes the feeder. The cartridge includes a port from which the powder is stored and withdrawn, and an open/close valve for opening and closing the port. The feeder includes a connection portion to which the cartridge is removably connected, a supply port configured to supply the powder in the cartridge connected to the connection portion into the feeder, and an opening/closing valve for opening and closing the supply port. The feeder is configured to insert the powder supplied from the supply port to the feeder into the nozzle, and the cartridge and the feeder are configured to form an enclosed space between the port and the supply port in response to the cartridge being connected to the connection portion.

Proposed is a method of producing an yttrium-based thermal spray coating. The method includes forming a coating on a substrate by atmospheric plasma spraying of an yttrium-based granular powder including at least one yttrium compound powder selected from the group consisting of Y.sub.2O.sub.3, YOF, YF.sub.3, Y.sub.4Al.sub.2O.sub.9, Y.sub.3Al.sub.5O.sub.12, and YAlO.sub.3, and a silica (SiO.sub.2) powder. The yttrium-based granular powder includes less than 10 w % of a Y—Si—O mesophase. Then yttrium-based thermal spray coating can exhibit low porosity, high density, and excellent plasma resistance.

Provided is a thermal spraying apparatus that forms a film on a target by thermally spraying a conductive powder by plasma, the thermal spraying apparatus including: a first electrode provided with a first cavity through which the conductive powder from a powder supplier passes; and a second electrode provided with a second cavity through which the conductive powder from the first electrode passes, in which the plasma is generated between the first electrode and the second electrode.

The invention relates to a method for producing a coating in which: a substrate is provided; and the substrate is provided with a coating, in particular by means of atmospheric plasma spraying, with a plasma torch having a torch nozzle being used, by means of which torch a plasma jet is generated from a supplied process gas, and with a supplied spraying material being applied to the substrate by means of the plasma jet in order to obtain the coating, wherein the torch nozzle is characterized by a nozzle diameter or a minimum nozzle diameter in the range of 4 mm to 8 mm, in particular 5 mm to 8 mm, preferably 5 mm to 7 mm, and wherein the process gas stream is at least 40 slpm. The invention further relates to a component comprising a substrate and a coating.

The present invention generally relates to an atmospheric spray process for producing a controlled conical shrouded oxygen gas stream designed to intercept a plasma effluent stream to inject and mix oxygen with powder particles contained in the plasma effluent prior to the molten power particles entrained in the plasma effluent solidifying on a substrate.

An example method that includes receiving, by a computing device, a geometry of the component that includes a plurality of locations on a surface of the component; determining, by the computing device, a respective target thickness of the coating for each respective location of the plurality of locations based on a target coated component geometry and the geometry of the component; and determining, by the computing device, a number of passes or velocity of a coating device for each respective position of a plurality of positions to achieve the respective target thickness for each respective location.

An example method that includes receiving a first geometry of a component in an uncoated state and a second geometry of the component in a coated state; determining a first difference between the second geometry and a first simulated geometry based on the first geometry and a first spray law comprising a plurality of first spray law parameters; iteratively adjusting at least one first spray law parameter to determine a respective subsequent spray law; iteratively determining a respective subsequent difference between the second geometry and a subsequent simulated geometry based on the first geometry and the subsequent respective spray law; selecting a subsequent spray law from the respective subsequent spray laws based on the respective subsequent differences; and controlling a coating process based on the selected subsequent spray law.

An example method that includes receiving a geometry of a component that includes a plurality of locations on a surface of the component; determining a first target trajectory including a first plurality of target trajectory points and a second target trajectory including a second plurality of target trajectory points, the first and second trajectories offset in a first direction, and the first and second plurality of trajectory points offset in a second direction; determining a respective target coating thickness of the coating based on a target coated component geometry and the geometry; and determining a respective motion vector of a coating device based on the first and second target trajectories to deposit the respective target coating thickness.