Method of cleaning a plasma coating torch utilizing at least one nozzle mounted so as to be directed at the plasma coating torch in order to subject an external surface of the plasma coating torch to a cleaning agent that removes spray material particles which have adhered to the external surface of the plasma coating torch during coating with the plasma coating torch, and such that the cleaning agent exiting the at least one nozzle and being directed toward the external surface and directly changing to a gaseous state from either a solid state or a liquid state.

Provided are a system and process for remanufacturing a waste cylinder assembly of an aircraft piston engine. The spraying apparatus includes a first power mechanism, a spray gun assembly and a second power mechanism. The first power mechanism drives the cylinder assembly to move in a horizontal direction and a vertical direction. The second power mechanism drives the spray gun assembly to rotate around a center of the blind hole and ensures that prepared coatings can be evenly distributed along an inner wall of the blind hole. A nozzle end of the spray gun extends into the blind hole, and the spray gun is adjustable relative to the center of the blind hole. A spraying distance is not fixed so as to change the spraying distance. Powder can be fully melted.

The present disclosure provides a heating system for performing thermal spray coating. The heating system includes (a) a thermal spray element configured to be coupled to a robotic arm, (b) a heating unit configured to be coupled to the robotic arm, (c) at least one processor, and (d) data storage comprising program instructions executable by the at least one processor to cause the heating system to perform functions including (i) receiving a first indication of a spray coating material positioned in the thermal spray element, (ii) receiving a second indication of a material of a substrate onto which the spray coating material is to be sprayed, (iii) heating the substrate for a time period until the substrate reaches a desired temperature that is determined based on both the spray coating material and the material of the substrate, and (iv) spraying the spray coating material onto the substrate.

Method and apparatus for monitoring and diagnosing gun performance is derived that can determine proper gun operation and if not operating properly diagnose potential causes for abhorrent operation. The voltage produced by the gun is sampled in real time and the frequency spectrum produced analyzed using FFT and then reducing the FFT pattern down to a set of numerical values or a signature that can be compared to known signatures for both correct operation and abnormal operation. Using best fit techniques the cause of any abnormal behavior can then be identified. The method can also be used to predict the end of hardware life and aid in production scheduling and spare parts acquisition by providing advanced notice of wear and usage.

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. 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 of the plurality of metallic anchoring materials.

Plasma spray apparatus for coating substrates, including at least a working chamber including a plasma torch and at least a substrate support, in which an inert gas or a mixture of inert gases is contained at a pressure which is close to the normal pressure, and at least a gas circuit, in communication with said working chamber, including recirculating means of the inert gases contained in said working chamber. The recirculating means include a closed loop, including a blower and a first heat exchanger communicating with said working chamber for extracting the inert gases and supplying a first fraction of the cooled inert gases back into a first portion of the working chamber, and at least a path, communicating with said closed loop and including a compressor and a second heat exchanger for supplying a second fraction of the cooled inert gases into a second portion of the working chamber.

A spray coating apparatus includes a cathode and an anode nozzle to form a pair. A front end of the anode nozzle is provided with three or more plasma jet jetting holes, and a spray material jetting hole is disposed at the center of an area surrounded by the plasma jet jetting holes. The spray material jetted through the jetting hole is fed into the center axis of a complex plasma arc or a complex plasma jet. The spray material jetted through the spray material jetting hole is melted at high thermal efficiency, to thereby enhance yield of coating film. Reflection of the spray material by the outer periphery of plasma flame, penetration of the spray material through plasma flame, and scattering of the spray material caused by reflection or penetration, due to the differences in particle diameter, mass, etc. of the spray material is prevented.

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. 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 of the plurality of metallic anchoring materials.

Various embodiments of the disclosure include a thermal coating powder, a system for providing a thermal spray coating, and a method for coating a component. The thermal coating powder may include fused and crushed yttria-stabilized zirconia, wherein the thermal coating powder is in a form of substantially spherically-shaped, solid particles. The system may comprise: a plasma spray gun apparatus having an exit annulus for releasing a plasma jet stream; and a powder injector port coupled to the plasma spray gun apparatus for supplying the thermal coating powder to the plasma jet stream. The method may include: providing a plasma spray gun apparatus including an exit annulus for releasing a plasma jet stream; and spraying the thermal coating powder on the component with the plasma jet stream from the plasma spray gun apparatus.

A system and method are provided to create porous surface coatings. In use, a method is included for receiving, at a plasma spray torch, inputs comprising metallic particles and carbon particles, using the plasma spray torch to cause in-situ nucleation of the inputs to synthesize carbon-containing composite materials, and flowing the synthesized carbon-containing composite materials onto a substrate. Some or all of the synthesized carbon-containing composite materials may include a surface layer and/or a bonding layer. Additionally, the method may include tuning the inputs based on tuning characteristics, the tuning characteristics including one or more of: porosity, heat transfer, or resistance to corrosion. Further, the method may include tuning the inputs to optimize temperature redistribution across a surface layer of some or all of the synthesized carbon-containing composite materials.