Patent ID: 11965251
Assignee: PRAXAIR S.T. TECHNOLOGY, INC.
Field: Surface technology, coating (Chemistry)
Classification: CPC C  B | IPC C

Claim 0:
1. A one-step method for creating a thin, fluid-tight, as-deposited coating without sealing the as-deposited coating, comprising:
providing a substrate;
providing a powder feedstock having a particle size ranging from 1 to 15 microns;
providing a thermal spray torch, said thermal spray torch comprising a combustion chamber with a comprising a nozzle downstream of the combustion chamber;
introducing a liquid fuel into the combustion chamber;
pre-mixing oxygen gas with an inert gas to produce diluted oxygen gas, wherein the pre-mixing occurs prior to the oxygen gas entering the combustion chamber, and wherein a flow ratio of the inert gas to the oxygen gas ranges from 8:92 to 50:50, wherein said inert gas is selected from the group consisting of nitrogen and argon, and wherein the pre-mixing of the oxygen gas with the inert gas excludes feeding air as a source of oxidant for the liquid fuel combustion;
introducing the diluted oxygen gas into the combustion chamber;
combusting the fuel with the diluted oxygen gas to generate a flame;
introducing the powder feedstock into the nozzle;
contacting the powder feedstock with the flame to produce substantially molten and semi-molten droplets; and
directing the substantially molten and semi-molten droplets to the substrate to form the thin, fluid-tight, as-deposited coating.