A method comprising: spraying a ceramic coating to a substrate to a thickness of at least 5.0 mils (127 micrometers) without quench; and after the spraying, directing a carbon dioxide flow to a surface of the coating.

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.

A powder feeding apparatus drops powder from a tank storing the powder to an oblique portion, and accumulates the powder on a plate disposed below the oblique portion. The plate is provided with a flat surface portion and a groove portion which is inverted from the flat surface portion to a lower part. The scraper moves powder which has accumulated to a higher level than a constant height on the flat portion and the groove portion, to an outer-side of the flat portion and smoothes the powder on the flat portion and the groove portion to a constant height. An ejector takes in powder which has accumulated on the groove portion of the plate by a suction opening, disposed at a front side of the scraper, in a relative moving direction of the plate, and discharges the powder from the discharge opening.

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 an uncoated component and a measured coating thickness of a coated test; determining a simulated coating thickness based on the geometry and a first spray law including a plurality of first spray law parameters; determining a difference between the simulated coating thicknesses and the measured coating thickness; iteratively adjusting at least one first spray law parameter to determine a respective subsequent spray law and determining a respective subsequent difference between the measured coating thickness and a subsequent simulated coating thickness based on the geometry and the respective subsequent spray law; selecting a subsequent spray law from the plurality of respective subsequent spray laws based on the respective subsequent differences; and controlling a coating process based on the selected subsequent spray law to compensate for the difference.

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.

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 m and not more than 10 m; 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 patent described the advantages of detonation plasma spraying, laser pyrolysis technologies, etc., being optimized by pulses with common parameters, like duration, slope for all mentioned above technologies.

For example, in some high temperature processes, using pulsed plasma or laser technology, plays vital important role the efficiency of plasma chemical processes. Since the plasma chemical reaction process efficiency is 20-30%, its value could be increased up to the thermodynamically feasible level of 60%.

The Shock waves created by electrical pulses disintegrates liquid particles up to Nano size fragments, accelerate them and finally formatted a coating with superior characteristics.

The influence of the pulses of radiation, detonation, electro impulse plasma can be generated by the same single pulse parameters of duration, slope, etc.

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.