Patent ID: 6896933

Claim:
A method of kinetic spray coating a substrate comprising the steps of: a) providing a mixture of particles comprising a first particle population and a second particle population, said first particle population having an average nominal diameter of from 75 to 106 microns and said second particle population having an average nominal diameter of from 75 to 300 microns; b) entraining the mixture of particles into a flow of a gas, the gas at a temperature below a melt temperature of the first particle population and below a melt temperature of the second particle population; c) directing the mixture of particles entrained in the flow of gas through a supersonic nozzle and simultaneously accelerating the first particle population to a velocity sufficient to result in adherence of the first particle population on a substrate positioned opposite the nozzle, while accelerating the second particle population to a velocity insufficient to result in adherence of the second particle population to either the nozzle or the substrate when it impacts the substrate.