Patent ID: 8794540
Filing Date: 2014-08-05
Classification: B05B,B23K,C23C,Y10T

Abstract:
1. A wire arc spray system comprising: a composite wire including a core region having a first material and a cladding surrounding the core region, wherein the cladding includes a metal, and the first material includes a polymer; a first wire delivery apparatus physically connected to the composite wire and configured to deliver the composite wire to an arc point; a second wire delivery apparatus configured to deliver a non-composite wire to the arc point; a propelling gas source for delivering a propelling gas to the arc point; an electrical source configured to create a first electrical polarity in the composite wire and a second electrical polarity in the non-composite wire, the second electrical polarity being opposite to the first electrical polarity; a mover adapted to control a distance between the arc point and a surface to be coated; and a controller configured to provide instructions to at least one of the mover, the electrical source, the propelling gas source and the first and second wire delivery apparatuses to propel molten droplets of a heated material on to the surface to be coated, wherein the heated material is created by an arcing of the composite wire and the non-composite wire at the arc point, and wherein the propelling of the molten droplets of the heated material creates a porous metal coating on the surface to be coated.