Patent ID: 7820238

Claim:
A method for forming a metal matrix composite coating comprising: providing a metal matrix powder having a particle range of from 20 to 55 microns; providing a ceramic reinforcing powder having a particle size of from 1 to 30 microns; combining from 5 to 50 volume percent of said ceramic reinforcing powder with a predetermined volume of said metal matrix powder; wet blending said metal matrix powder with said ceramic reinforcing powder to form a metal matrix composite; said wet blending step comprising adding a liquid carrier to form a slurry and adding high density zirconia or alumina balls in a range of from 20 to 50 wt % to said slurry; drying said slurry to form a dry metal matrix composite material in powder form; removing said balls and any large particles or agglomerates that may have formed; providing a substrate; forming a supersonic gas jet using a converging/diverging spray nozzle; introducing said metal matrix composite powder into said supersonic gas jet; and depositing said metal matrix composite powder at supersonic speed onto a surface of said substrate using said supersonic jet such that said metal matrix composite powder plastically deforms and bonds to said substrate and itself upon impact with said substrate surface trapping said reinforcing powder.