Patent ID: 7390561

Claim:
A thermal sprayed metal or metal alloy material surface infused or impregnated composite object comprising a solid composite material of fiber and resin in which at least a portion of the resin composite material is infused or impregnated into the thermal sprayed metal or metal alloy material surface of a thermal spray metal or metal alloy material layer, said thermal spray metal or metal alloy material layer having an inner dense layer of thermal spray metal or metal alloy_material and a more porous outer layer as the thickness of the thermal spray metal or metal alloy material layer increases; wherein said thermal spray metal or metal alloy_material layer has a thickness of between 0.0001 and about 3 inches, said inner layer has a theoretical density of between about 95 and about 99.9 percent and comprises from about 5 to about 50 percent of the thickness of said thermal spray metal or metal alloy material layer, and said outer layer has a porosity of between about 5 and about 95 percent and comprises from about 5 to about 50 percent of the thickness of said thermal spray metal or metal alloy material layer.