IMPROVEMENTS RELATING TO METAL SPRAYING APPARATUS

Abstract: A metal spraying apparatus comprises a gun having convergent guide passages (36, 38) through which metallic wires are fed. An electrical potential is applied across the wires, by conductor elements (54), to cause arcing between the wires were they emerge from the guide passages, which melts the wires. A stream of compressed air causes molten metal droplets to be carried from the arcing zone towards the surface to which a metallic coating is to be applied. The apparatus also comprises a supplying device, to supply electricity and air under pressure to the gun. The conductor elements extend within conduits (18) through which air is fed to the gun, and the gun comprises a valve (9) for cutting off the flow of air through the gun. The supplying device comprises control means (82) which is responsive to such cut off, to cut off the supply of electricity to the gun.

Description: Title: "Improvements relating to Metal Spraying Apparatus" Description of Invention. A conventional metal spraying apparatus comprises a spraying device comprises a body, feeding mechanism for simultaneously feeding two metallic wires or rods (here¬ inafter referred to for convenience as "wires") through two guide passages which converge forwardly in the direction of wire feed, connecting means which may be connected to a supply of electricity remote from the device and which establishes an electric potential across said wires to cause an arc to be established between the wires where they emerge from said guide passages so as to melt with wires, and delivery means for delivering a stream of compressed air or other non-combustible gas (hereinafter referred to for convenience as "an air jet") relative to the wires and the arc therebetween so as to cause molten metal droplets to be carried away from the arcing zone on the air jet from the spraying device towards a surface to which a coating of metal is to be applied. Such a metal spraying device is hereinafter referred to as being of the kind specified and an example of such a device is described in the Specification of our U.K. Patent No. 1,540,810. Conventionally the wires are drawn by the feeding means from reels; in particular for hand-held spraying devices, the reels are mounted separately from the device itself, and the feeding means operates to draw the wires from the reels into guide sleeves extending from the guide passages of the spraying device. OMPI /,, WIPO . . Conveniently, the feeding mechanism comprises an air motor, so that, additional to the air supply needed to- -establish the air jet, an air supply must also be provided to drive the air motor. Further air may be utilised to establish air flow arond the wires, to reduce the tendency for them to overheat whilst in the guide passages and to blow detritus from the wires. The particle size of the atomised metal which is carried from the arcing zone, and the smoothness of the finished metallic coating, is dependent upon the rate of air flow through the arcing zone. For this reason, it is desirable to use a high air flow rate through the arcing zone, and typically an air flow rate of about 50.cu.ft. of air per minute is utilised. In view of the air pressures conventionally used in factory premises and in view of the requirement to retain flexibility of the metal spraying device, it is conven¬ tional practice to utilise separate conduits, usually in the form of flexible hoses for the air jet and for the air motor, since if all the air were supplied through a single hose, problems would be caused by the size and inflexibility of the hose. Aditionally,- conventionally the spraying device is connected to a source of electricity by two insulated conductors, which conventionally are copper stranded cable having an effective cross-sectional area of 70 sq.mm. capable of delivering a current of 300 amps to the metal spraying device. Thus, a conventional spraying device of the kind specified may comprise six supply conduits, one being an air hose for the -air jet, one being an air hose for the air motor, two wire guide sleeves for the wires them- sevles, and two insulated electrical conductors. It is frequently desired to spray a metal surface by the use of a spraying device of the kind specified, in the form of a hand-held gun. Typically, such a gun weighs about Ϊ4lbs., but, because of the six supply conduits, is not easy- to operate such a spray gun in a manner which provides high quality metal spray finishes. An additional- difficulty which is encountered is that it is often necessary to use the device some distance from the supply of electricity, some of the supply conduits being trailed across the floor. A not uncommon problem occurs when a fork lift truck or the like requires to traverse the floor area, since utilising the conventional copper stranded cable construction, the weight of a fork lift truck on these can crush the conductor causing a hot spot to develop. Thus, it is a general requirement that a fork lift truck shall not be driven across the insulated •conductors, but because of the difficulty involved in adhering to this rule, it is not always observed. It is one of the various objects of this invention to provide a metal spraying device of the kind specified in which some at least of the problems set out above are reduced. According to a first aspect of this invention there is provided a metal spraying device comprising a body, feeding mechanism for feeding two metallic wires through guide passages which converge forwardly in the direction of wire feed, connecting means which may be connected to a supply of electricity remote from the device and which establishes an electric potential across said wires to cause an arc to be established between the wires where they emerge from the guide passages, and means for delivering an air jet relative to the wires and the arc therebetween so as to cause molten metal droplets to be carried away from the arcing zone on the air jet from the device towards a surface to which a coating of metal is to be applied, wherein electric current is supplied to the device along conductor elements extending within conduits through which air .is fed under pressure to the device. Preferably, some at least of the air which is fed under pressure through said conduits is utilised to establish the air jet; Additionally, where the feeding mechanism comprises an air motor, some at least of the air which is fed under pressure through said conduits is utilised to drive the air motor. Further, advantageously some at least of the air which is fed under pressure through the conduits is fed to the guide passages through which the . metallic wires are fed, reducing the temperature of the metallic wires, and blowing detritus therefrom so that the wires exit from the guide passages in a relatively clean state. Preferably, the conductor elements are of solid cross-section, and advantageously a plurality of con¬ ductor elements extend within each conduit, thus provid¬ ing a relatively high surface area/cross-sectional area ratio. In this manner, by combination of one air and one electricity supply in for example a single flexible hose, the number of supply connectors to the supply device may be reduced, typically from six to four. The combined air and electricity feed conduits may still be provided by 3/8" hose. Thus, where seven conductors of solid cross-section extend through each hose, each conductor being for example of 1.5 mm. diameter, the effective diameter of the hose is reduced, as far as air flow capability is concerned, to an O / ,, WI equivalent 5/16" hose. Two such hoses have an effective _ delivery rate of 90. cu.ft. per minute, which allows both adequate air to be supplied to the air motor for feeding of the metallising wires, and a significantly higher air feed for the air jet, .with superior spraying results. Additionally, flow of air over the conductor elements retain them cool, maintaining the electrical resistance at a relatively low level. This allows a total conductor cross-section to be used which is smaller than would otherwise be the case, and reduces the power consumption of the device. Further the flow of air over the conductor elements increases the temperature of the air delivered to the arcing zone, typically to 100°C, which, further signifi- cantly improves the quality of spraying, not only because of the approcah in temperature of the air towards that of the melted wire, reducing deleterious effects caused by a ' high temperature disparity, but also improves quality because of the removal of moisture from the jet stream which is afforded by this increase in temperature. It will be appreciated that this invention is particularly useful where the metal spraying device is in the form of a hand-held gun, since in this case the reduction in weight, and increase in flexibility afforded by the reduction in the number of connections is most useful. However, certain aspects of the invention, particularly in relation to the increase in the temperature of the air jet, and the consequent improve¬ ment in the quality of spraying which may be achieved thereby, together with a reduction in the power consumption on the device by virtue of the cooling effect of the air flow of the conductor elements, may be applied to metal spraying devices other than in the form of hand¬ held spray guns. Additionally, since it is common practice to operate a metal spraying device of the kind specified some distance froa the source of electric power and the source of compressed air, it is desirable to provide on the device a means by which the -supply of electricity can be switched on or off, rather than requiring the operator to return to the source. This is coneventionally effected by the use of a low power electric supply cable extending between the source of electricity and the spraying device, and in particular to a switch on the spraying device which an operator may use to switch the supply of electricity to the device on or off. Such control cables are additionally cumbersome, and may at times be hazardous. According to a second aspect of this invention, there is provided apparatus for applying a coating of metal to a surface and comprising:- a metal spraying device comprising a body, feeding mechanism for simultaneously feeding two metallic wires through guide passages which converge for¬ wardly in the direction of wire feed, connecting means for connecting an electric potential across said wires to cause an arc to be established between the wires where they emerge from said guide passages so as to melt the wires, and delivery means for delivering a stream of compressed air relative to the wires and the arc therebetween so as to cause molten metal droplets to be carried away from the arcing zone on the air jet from the device towards the surface to which a coating of metal is to be applied; and a supplying device, adapted to supply electricity and air under pressure to the device; wherein the spraying device is connected to the supplying device by conduits through which electric power and air under pressure are supplied to the . device, wherein the spraying device comprises a valve which may be operated to cut off or reduce • the flow of air through the body, and the supplying device has associated therewith control means which is responsive to such cut off or reduction, to cut off the supply of electricity to the device. 0 The valve may be operated in consequence of operation of the feeding mechanism. Thus, where the feeding mechanism comprises an air motor, the valve is provided by the the trigger o.f the device which operates the air motor. Thus, when operation of the air motor 5 teminates, the supply of electricity to the device is similarly terminated, . and when the air motor is restarted, supply of electricity to the device is re¬ established. Alternatively however, the valve is operative in the 0 stream of air which establishes the air jet, and is preferably separate from the air flow to the air motor. In this manner, merely by cutting off the air jet by means of the valve, the operator may effect electrical disconstruction from the electricity power source. 5 Advantageously, the control means which is responsive to cut off or reduce the air flow through the device to cut off the supply of electricity to the device, is provided by the pressure switch (as aforesaid) which is- responsive to an increase in air pressure at the Q supplying device. The second aspect of the invention is particularly useful where the metal spraying device is in the form of a hand-held gun, and is particularly advantageous in QMPI_ reducing the weight of such a gun, and increasing its flexibility when utilised in conjunction with the first aspect of the invention. Thus, where electric current is supplied to the device along conductor elements extending with the conduits through which air under pressure is fed to the spraying device, should air flow through either of the hoses be impeded, by for example a heavy weight crushing the conduit, the supply of electricity to the spraying device will be cut off immediately. However, should a fork lift truck drive over the hose, although a momentary interruption to the air flow will be produced, because of the nature of the conductive elements, and the resilience of the hose itself, ■ air flow will almost immediately be continued without any significant dis- turbance to the air jet, and without the requirement for the spraying device to be shut down. It will however be appreciated that the second aspect of the invention may also be used to advantage in a metal spraying device, the electricity supply and compressed air supply to which are separate. There will now be give a detailed description, to be read with reference to the accompanying drawings, of a metal spraying apparatus, comprising a hand-held spraying device, which is a preferred embodiment of this invention, and which has been selected to illustrate the invention by way of example, with reference to the accom¬ panying drawings in which:- FIGURE 1 is a side elevation of the device which i-s the preferred embodiment; FIGURE 2 is a vertical sectional view of the device taken on the longitudinal centre line thereof; FIGURE 3 is a vertical sectional view, taken on the line III-III of Figure . 2, of part * of a manifold assembly of the device? FIGURE 4 is a front elevation of the device; FIGURE 5 is a sectional view taken on the line V-V of Figure 3; FIGURE 6 is a plan view, part in horizontal section, of the device; FIGURE 7 is an elongate view of part of Figure 6; and FIGURE 8 is a schematic side elevation showing the spraying device in conjunction with a supplying device for the supply of electricity and air under pressure to the spraying device, and which together with the spraying device, form the apparatus which is the preferred embodi¬ ment of this invention. The preferred embodiment of the invention comprises a metal spraying device, in particular a hand-held metal spraying gun, and is similar in certain respects to the device illustrated by way of example in the Specification of our U.K. Patent No. 154,810, to which reference may be made for details of construction and operation not here¬ inbefore given. The metal spraying gun comprises a housing 6, a manifold assembly 8 secured to a forward end of the housing, a stem portion 14 secured to and extending forwardly from the manifold assembly, and a head 16 secured to a forward end of the stem portion 14. _ OMPI _ The manifold assembly 8 comprises a central portio 10 of insulating material (see Figure 3) and two outer conductive portions 12 secured to the central portion 3.0 The spray gun also comprises two supply conduits 18, i 5 the form of rubber hose of 3/8" diameter, each of whic define an interior supply passage 20, and each of whic is connected to one of the outer portions 12 of th manifold assembly by a screw fitting 22. The manifold assembly 8 comprises two passages 24 ° each of which is in connection with one of the suppl passages 20, and which extend to a cross passage 26 (se also Figure .5). A further cross passage- 28 in th central portion 10 extends through the passage 26, a upper end portion extending to a transverse passage 3 5 (see Figure 7) and to two supplementary air passages 4 and a lower end portion extending to a fitting 31 t which a flexible conduit 32 may be connected. Mounted in the passage 28, and operative between th cross passage 28 and the passage 30, and the air passage 0 40, is a spool valve 9 having a central bore, a centra outlet and two transverse outlets. A shaft of the spoo valve extends upwardly through the manifold assembly 8, and has secured thereto a handle 9a. by which the spoo valve may be rotated within the passage 28. When th 5 spool valve 9 is in its operative position (shown i Figure 5) the cross passage 28 is in communication wit • the transverse passage 30 by way of the central outlet, and the passage 28 is in communication with the supple mentary air passages 40 by way of the transverse outlet of the spool valve. However, the spool valve 9 may b rotated axially through 180 , to an inoperative position, in which communication between the cross passage 28 an the transverse 30 is blocked, whilst communicatio between the cross passage 28 and the supplementary ai passages 40 is maintained. OM 11 The head 16 is mounted on the stem portion 14, the head being provided with an inlet 59 into which an end portion of the stem 14 is secured. The head 16 is formed in one piece from an insulating material, preferably a ceramics material, by a machining operation. Alternat¬ ively, however, the ' head may be formed from plastics material (see Figure 7). Extending axially through the head from the inlet 59 is an air passage 60 which constitutes delivery means, through which compressed air may be fed from an - axial passage 34 of the stem. Extending through the head, lying in axial plane thereof, are two guide passages 62,62, said guide passages converging towards and exist¬ ing through a forwardly presented end face 58 of the head. Extending through the housing 6, one either side of the spray gun (Figure 6) are two guide tubes 36, each defining an interior guide passage 38. At a forward end region of the spray gun, the guide tubes 36 converge, and at a point adjacent the head 16, the guide passages 38 are each in alignment with one of the guide passages 62 of the head 16. Secured to an underside of the housing is an air motor 42, (Figures 1 and 2). In operation of the air motor initiated by a trigger lever 43, the air motor drives gear wheels 44 and 46 to axially rotate a central spindle 48. These in turn are connected to feed wheels 50 which extend through slots in the guide tubes 36, the air motor, together with the gear wheels 44 and 46, the central spindle 48 and - feed wheels 50 constituting feeding mechanism of the spraying device. In the use of the spray gun, metallising wires, in the form of elongate rods of circular cross-section, Wl OMPI /., WIPO - . and W2, are fed through the guide passages 38 in the guide tubes 36, -and into the guide passages 62 of the head 16. By operation of the air motor 2, the feed wheels 50 grip these metallic wires, and feed them along the guide tubes 36. in . the direction of forward convergence of the guide tubes and into the head. Extending through each of the two supply conduits 18 is a conductor means in the form of a plurality of conductor rods 54 of solid, conveniently circular cross- section. In the preferred embodiment, in each suppy conduit 18 there are seven such conductor rods, the diameter of each being 1.5 mm. At the point where each supply conduit is connected to the manifold assembly, conductive contact is established between the conductor rods and one of the two outer conductive portions 12 of the manifold assembly. Each guide tube 36, at a point where it passes through the manifold assembly, comprises a pressure contact element 37, which is urged by a spring towards .the longitudinal axis of the guide passage 38 to ensure good electrical contact with the metallising wire therein. The ends of the supply conduits 18 remote from the metal spraying gun are connected, to a supplying device 80 of the apparatus (see Figure 8) adapted to supply air under pressure, (conveniently about 120 p.s.i.) and the conductor rods 54 of each are connected to a respective supply of direct current. Conveniently the connection of each of the supply passages 20 to the source of air under pressure is carried out through a pressure sensitive switch, such as is indicated at 82 in Figure 8, each of which being responsive to a build up of pressure in its rspective supply passage to shut off the supply of electricity to both of the conductor rods. OM In the use of the metal spraying apparatus which is the preferred embodiment of this invention, the supplying device may be activated to supply compressed air to both the supply conduits 18, and to establish a potential difference across the two sets of conductor rods 54. Air flows through the two supply passages 20, via the passage 24 of the outer.sections of the manifold assembly to the cross passage 26 of the central insulated portion thereof. The bulk of the . air flow then flows upwardly through the cross passage 28 and with the spool valve 9 in its operative position, through the transverse passage 30, from which it flows along the axial passage 34 of the stem portion 14 and into the air passage 60 of the head 16, emerging therefrom in the form of an air jet. Simultaneously, some air flows downwardly through the cross passage 28 along the conduit 32, to the air motor 42, which may be operated by means of the trigger 43 to drive the feed wheels 50, to commence feeding of the two metallising wires through the guide passages 38 and into the head 16. Electrical contact is established between each of the wires and a respective set of conductor rods 54 via one or other of the outer conductive portions 12 of the manifold assembly, such contact being ensured by the pressure pads 37. Thus, as the two wires emerge from the- guide passages 62 at the end face 58 of the head, an electric arc is established between the wires. This produces a continuous melting of the wires as they are continuously fed forwardly, and droplets of molten metal are carried forwardly from the spray gun on the air jet passing through the air passages 60 of the head. On release of the trigger 43, the air motor 42 ceases operation, and the arc breaks down as the leading end portions of the two metallising wires are eroded. However, upon recommencement of operation of the air ■motor, an arc is again established, and metal spraying may be continued. During operation of the apparatus, a relatively small air flow through- the supplementary air passage 40 . (see Figures 3 and 6) takes place which establishes flow of air within the two guide passages 38 around the two metallising wires. This prevents or minimises tendancy for the metallising wires to carry into the guide passages 38 small pieces of foreign matter, which might otherwise be carried forwardly into the arcing zone, or interfere with the electrical contact between the pressure pads 37 and the metallising wires themselves. Additionally, such air flow tends to reduce the temperature of the metallising wires, and reduces tendancy for them to melt or oxidise within the guide passages 38. By the use of this invention, flow of air through the supply conduits 18 around both sets of conductor rods 54 serves to reduce the temperature of the conductor rods, notwithstanding the high current load carried thereby. This allows a total cross-sectional area of electrical conductor to be used to carry current from the distribution box to the spray gun, which is sufficiently small so as not to interfere significantly with the quantity of air which may be delivered to the spray gun by the use of the two supply conduits. Specifically, in the preferred embodiment, the effective cross-sectional • area of the two conduits (as far as air flow is concerned) is reduced from a nominal 2 x 3/8" to 2 x 5/l6". This allows an effective delivery rate of 90 cu.ft. per minute to the spray gun, which allows both adequate air to be supplied to the air motor for feeding the metallising wires, and a significantly higher air feed for the air jet with superior spraying results. O . " W Additionally, in view of the temperature increase caused in the air due to its flow over the conductor rods 54, moisture is removed from the air, and this, together with the increase in temperature of the air itself, increase the quality of spraying which may be achieved by the use of a spray gun. In the event of a momentary blockage of air flow, such as a fork lift truck being driven over one or both of the supply conduits, the increase in pressure sensed 10 by one or both the pressure sensitive switches 82 need not be such as will cause a break in the supply of electricity to the two sets of conductor rods. However, if such air flow is impeded for any significant period of time, the pressure sensitive switch 82 will be operative -^ to cut off the supply of electricity, to prevent over heating of the conductor rods. By rotation of the spool valve 9, the operator can readily cut off the supply of compressed air to the head 16. Such closing of the spool valve 9 is also effective 20 to significantly reduce the flow of air through the spraying gun, to an extent such that there is a build up of air under pressure within the conduits 18, and after a very short time a similar operation of the pressure sensitive switch hereinbefore mentioned is caused to cut 25 off the supply of electricity to the spraying gun, in the same way as blockage of the air flow conduits may cause a break in the supply of electricity. In this manner, the operator may electrically isolate the spray gun from the source of the electricity 30 (which may be some distance from the spraying gun) with¬ out the need for separate control means extending from the spraying gun to the electricity supply. - RE CT OMPI _ * ,, IPO. ,, In the arrangement shown in Figure 3, closing of the spool valve 9, whilst being effective to terminate the flow of air through the transverse passage 30, never¬ theless maintains air power through the conduit 32, to the air motor 42. The rate .of utilisation of air by the air motor is insufficient significantly to vary the operation of the pressure sensitive switch to closing of the spool valve 9, and this allows the facility of operation of the air motor to advance the metallising wires within their conduits to a point of contact in the vicinity of the arcing zone, preparatory to a recommence¬ ment of the metal spraying operation. In the preferred embodiment, closing of the spool valve is not effective to cut off the supply of air to the supplementary air passages 40. It will however be appreciated that whereas in the preferred embodiment the feeding mechanism is provided by an air motor, if desired, an electric motor may be used to advance the metallising wires through the device. In such a construction, advantageously some air (for example that flowing through the conduit 32) may be utilised to cool the electric motor. It will be apprecited further that whereas in the preferred embodiment, cutting off of the high current electricity supply to the spraying device is effected by a pressure sensitive switch located in one or both of the air supply conduits, or in an air distribution box to which such conduits are connected, other forms of flow sensing means may be utilised, such as simple pressure differential switches, or vane switches which are retained in a first condition by actual flow of air, and which moved to a second condition (corresponding to a cutting off of the high current electricity supply) by cessation or significant reduction in the rate of flow of air.

Claims: CLAIMS: 1 A metal spraying device comprising a body, feeding mechanism for feeding- two metallic wires through guide passages which converge forwardly in the direction of wire feed, connecting means which may be connected to a supply of electricity remote from the device and which establishes an electric potential across said wires to cause an arc to be established between the wires where they emerge from the guide passages, and means for delivering an air jet relative to the wires and the arc therebetween so as to cause molten metal droplets to be carried away from the arcing zone on the air jet from the device towards a surface to which a coating of metal is to be applied, wherein electric current is supplied to the device along conductor elements- extending within conduits, through which air is fed under pressure to the device. 2. A metal spraying device according to Claim 1 wherein some at least of the air which is fed under pressure through said conduits is utilised to establish the air jet. 3. A metal spraying device according to one of Claims 1 and 2 wherein the feeding mechanism comprises an air motor, and some at least of the air which is fed under pressure through said conduits is utilised. to drive the air motor. 4. A metal spraying device according to any one of the preceding claims wherein some at least of the air which is fed under pressure through the conduits is fed to the guide passages through which the metallic wires are fed. 5. A metal spraying device according to any one of the preceding claims wherein the whole of the air supply req ire by the device is provided by the air which is fed under pressure through said conduits. 6. A metal spraying device according to any one of the preceding claims wherein the conductor elements are of solid cross-section. 7. A metal spraying device according to any one of the preceding claims wherein a plurality of conductor elements extend within each conduit. 8. Apparatus for applying a coating of metal to a surface, and comprising:- (a) a metal spraying device comprising a body, feeding mechanism for simultaneously feeding two metallic wires through guide passages which converge forwardly in the direction of wire feed, connecting means for connecting an electric potential across said wires ' to cause an arc to be established between the wires where they emerge from said guide passages so as to melt the wires, and delivery means for delivering a stream of compressed air relative to the wires and the arc therebetween so as to cause molten metal droplets to be carried away from the arcing zone on the air jet from the device towards the surface to which a coating of metal is to.be applied; and (b) a supplying device, adapted to supply electricity and air under pressure to the device; wherein the spraying device is connected to the supplying device by conduits through which electric power and air under pressure are supplied to the OMP " WIP device, wherein the spraying device comprises a valve which may be operated to cut off or reduce the flow of air through the body, and the supplying device has associated therewith control means which is responsive to such cut off or reduction, to cut off the supply of electricity to the device. 9. Apparatus according to Claim 8 wherein the valve is operated in consequence of operation of the feeding mechanism. ° 10. Apparatus according to Claim 9 wherein- the feeding mechanism comprises an air motor, and the valve is provided by the trigger of the spraying device which operates the air motor. 11. Apparatus according to Claim 8 wherein the valve is 5 operative in the stream of air which establishes the air jet. 12. Apparatus according to any one of Claims 8, 9, 10 and 11 wherein the control means is provided by a pressure switch which is responsive to an increase in air 0 pressure at the supplying device.- 13« Apparatus for spraying a coating of metal to -a surface, and comprising a metal spraying device according to any one of Claims 1 to 7, and a supplying device, adapted to supply electricity and air under pressure to the spraying device, two conduits extending from the supplying device to the metal spraying device, within which conductor elements for the supply of electric current to the spraying device extend, and through which air under pressure is fed to the delivery means, the ° supplying device comprising a pressure-responsive switch, which is responsive to a cessation or reduction in the rate of flow of air from the supplying device to the spraying device, to cut off the supply of electricity to the spraying device. O I

Inventors: ASHMAN S
Applicants: ASHMAN S, METALLISATION LTD
Application year: 1979
Main classification: B05B7
IPC codes: B05B7, C23C4, H01B13