[Problem] Upon application or film formation of a particulate matter to/on an object, the particulate matter moving with a speed is heated in a time duration from a suction port for particulate matter to the object, thereby softening or melting at least some of the particulate matter when the particulate matter is applied to the object.

[Solution] A particulate matter is heated by means of induction heating or laser in a time duration from a suction port for particulate matter to an object, so that at least some of the particulate matter is softened or melted at a relatively low temperature on the object in synergy with the collision energy of the particulate matter with the object, thereby enabling the application or film formation of the particulate matter.

An apparatus and method perform supersonic cold-spraying to deposit N and P-type thermoelectric semiconductor, and other polycrystalline materials on other materials of varying complex shapes. The process developed has been demonstrated for bismuth and antimony telluride formulations as well as Tetrahedrite type copper sulfosalt materials. Both thick and thin layer thermoelectric semiconductor material is deposited over small or large areas to flat and highly complex shaped surfaces and will therefore help create a far greater application set for thermoelectric generator (TEG) systems. This process when combined with other manufacturing processes allows the total additive manufacturing of complete thermoelectric generator based waste heat recovery systems. The processes also directly apply to both thermoelectric cooler (TEC) systems, thermopile devices, and other polycrystalline functional material applications.

A thermal spray apparatus to apply coatings to external and internal surfaces in restricted areas is provided. The apparatus includes: a combustion chamber having a primary passage for combustion of fuel received through a fuel input line with oxygen or air received through an oxidizing gas input line; a divergence section located downstream of the combustion chamber; an elbow housing located downstream of the divergence section. A nozzle housing retaining a nozzle having an injection zone and a nozzle throat; a convergence section retained between the elbow housing and the nozzle housing; a feedstock injector for the injection of feedstock material into the injection zone of said nozzle; and a plurality of passageways extending through the combustion chamber, the divergence section, the elbow housing, and the convergence section for passing a coolant therethrough.

A nozzle for a thermal spray gun and a method of thermal spraying are disclosed. The nozzle has a combustion chamber within which fuel is burned to produce a stream of combustion gases. The streams of heated gases exit through a pair of linear exhausts which are located on either side of an aerospike. The streams converge outside the nozzle and powdered coating material is introduced into the converging streams immediately downstream of the aerospike. The coating material is heated and accelerated before impacting on a substrate to be coated.

A nozzle for a thermal spray gun and a method of thermal spraying are disclosed. The nozzle has a combustion chamber within which fuel is burned to produce a stream of combustion gases. The stream of heated gases exits through an annular exhaust which is located around an aerospike. The stream converges outside the nozzle and powdered coating material is introduced into the converging stream immediately downstream of the aerospike. The coating material is heated and accelerated before impacting on a substrate to be coated.

A thermal sprayer system includes an injector conduit in communication with an injector and a first valve for selectively directing a coating fluid through the injector conduit. A flush fluid conduit is in communication with the injector conduit for directing a flush fluid through the injector conduit. A pressurized air conduit is in communication with the injector conduit for directing a pressurized fluid through the injector conduit.

A method for fabricating an electrical conductor on a substrate by cold spraying includes propelling a solid powder composition that includes copper and highly oriented pyrolytic graphite using a gas propellant, and directing the solid powder composition towards the substrate at a velocity sufficient to cause the solid powder composition to undergo plastic deformation and to adhere to the substrate to deposit the electrical conductor thereon.

Tunable thermoplastic polymer sealants and tunable conductive thermoplastic polymer sealants, and edge seals and fillet seals produced from such sealants; and substrates, components and objects comprising the tunable edge seals and fillet seals, and methods for making and applying such edge seals and fillet seals are disclosed.

Tunable thermoplastic polymer powder feedstock formulations and tunable conductive thermoplastic polymer powder feedstock formulations are disclosed for delivery to a high-velocity sprayer, along with tunable coatings made from the disclosed formulations and methods for coating installed fasteners, and fasteners, fastener/substrate interfaces and substrates coated with the tunable thermoplastic polymer coatings.

Tunable thermoplastic polymer powder feedstock formulations and tunable conductive thermoplastic polymer powder feedstock formulations are disclosed for delivery to a high-velocity sprayer are presently disclosed, along with tunable coatings made from the disclosed formulations, and methods for delivering such tunable thermoplastic polymer coatings to substrates.