Patent ID: 9328918
Filing Date: 2016-05-03
CPC Classification: B05B,C23C,F23C,F23D,Y10T

Claim Text:
1. A method of forming an article with a coating comprising: providing a spray gun comprising a combustion chamber having an inlet side and an outlet side; providing a combustion zone between the inlet side and outlet side of the combustion chamber; providing a permeable burner block in the combustion zone; providing a fuel and an oxidizer inside the combustion zone; initiating combustion inside the combustion zone to form a combustion gas stream comprising combustion gases; introducing a feedstock mixture comprising a feedstock material and a liquid carrier into the combustion gas stream present in the combustion chamber when the temperature of the combustion gas stream is greater than the melting point of the feedstock material, creating an entrained feedstock stream and expelling the entrained feedstock stream from the spray gun through a nozzle to form a coating on a surface of the article, wherein the feedstock material is maintained at a temperature below its melting point by the liquid carrier when the feedstock mixture is introduced into the combustion chamber, and during spraying of the feedstock material so that the feedstock material does not melt during spraying; and wherein the median particle size of feedstock material is less than about 10 microns, and the feedstock material comprises a metal or a metal alloy.