A suspension plasma spray feeder apparatus for delivering a suspension from a suspension source to a plasma spray gun. The feeder apparatus comprises a suspension line and a vibrator mounted to vibrate the suspension line.

A thermal spray assembly (10) for transforming precursor material (60) into a layer of deposited material joined to a substrate body. A plasma torch produces a plasma jet from a plasma nozzle (28) and a feeder mechanism (30) guides the precursor material into the plasma jet in use and is capable of providing a feeder orifice when in an open condition. The feeder mechanism (30) is provided with a distribution chamber configured for guiding moving precursor material azimuthally around the plasma torch, a plurality of deflector structures (38) configured for deflecting the precursor material (60) from the distribution chamber and guiding it into a guide chamber configured for guiding the precursor material (60) to the plasma jet in use.

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 method for applying a thermal barrier coating according to an embodiment, includes: a step of forming a top coat layer on a bond coat layer formed on a heat-resistant alloy base material of an object. The step of forming the top coat layer includes forming the top coat layer by thermal-spraying a suspension, which contains ceramic powder, with atmospheric pressure plasma spraying, while cooling a portion of a plasma flame by supplying water as a cooling fluid to a periphery of the plasma flame at a supply rate of not less than 25 ml/min and not greater than 100 ml/min.

A thermal spray assembly (10) for transforming precursor material (60) into a layer of deposited material joined to a substrate body. A plasma torch (20) produces a plasma jet from a plasma nozzle (28). A feeder mechanism (30) guides the precursor material (60) into the plasma jet in use and provides a feeder orifice (70) when in an open condition. The feeder mechanism comprises a guide chamber (34) and a moveable guide mechanism (32), and the guide chamber is capable of guiding the precursor material to the feeder orifice, through which the precursor material can move from the guide chamber and enter the plasma jet at a variable mean distance from the plasma nozzle (28) in response to movement of the guide mechanism (32).

A small-size axial powder feeding inner hole plasma spraying gun comprises a nozzle with one end fixed on one side of a front gun body through a nozzle gland and the other end extending to the other side of the front gun body; an insulator arranged between the front gun body and a rear gun body; a powder feeding frame fixedly connected to the rear gun body internally provided with a powder inlet channel, a cathode seat of a cathode being connected to the powder feeding joint, a cathode head extending into a spray hole channel of the nozzle, and an annular cavity being formed between the cathode head and an inner wall of the spray hole channel; an air inlet channel arranged on the front gun body and communicated with the annular cavity; and a cooling channel with an interior introduced with cooling water.

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.