Patent ID: 6674047
Filing Date: 2004-01-06
Classification: B23K,C23C

Abstract:
A cored wire electrode for a thermal spray or welding apparatus, comprising:a sheath; and a multiplex powder composite that is contained within the sheath before the sheath is exposed to an electrical current in a thermal spray or welding environment, the composite comprising: a powder with a group of particles consisting of specie (A), comprising micron sized particles having an average diameter of about 1Ã—10âˆ’6 meters and specie (B), consisting of sub-micron sized particles, specie (B) including specie (C), comprising nano-scale particles having an average diameter of about 1Ã—10âˆ’9 meters, and specie (1), also comprising particles sized between specie (A) and specie (C), species (A) and (B) mechanically cooperating to promote smooth powder flow, which facilitates compaction of the cored wire, wherein the multiplex powder composite has the characteristics of relatively uniform density, wherein the particles of specie (C) move relatively easily in relation to those particles of specie (A) during compression of a sheath in which they are contained during mechanical reduction steps to which the sheath is subjected in manufacture of the cored wire electrode, thus reducing clumping or island-void problems that may adversely affect stiffness or malleability of the cored wire electrode.