Patent ID: 7125586

Claim:
A method of kinetic spray coating a substrate ( 86 , 92 ) covered by a plastic-type material ( 82 , 84 , 90 ) comprising the steps of: a) providing particles of a material to be sprayed having an average nominal diameter of from 600 to 1400 microns; b) providing a supersonic nozzle ( 54 ) having a converging region ( 56 ) connected to a diverging region through a throat ( 58 ); c) providing a substrate material ( 86 , 92 ) covered by a plastic-type material ( 82 , 84 , 90 ) and positioned opposite the nozzle ( 54 ); d) directing a flow of a heated main gas through the nozzle ( 54 ); and e) kinetic spraying the particles by entraining the particles in the flow of the heated main gas and accelerating the particles to a velocity sufficient to result in the particles passing through the plastic-type material ( 82 , 84 , 90 ) and adhering to the substrate material ( 86 , 92 ) upon impact.