Patent ID: 7763823

Claim:
A microplasma spray apparatus for coating at least a portion of a component in a gas turbine engine, comprising: a microplasma gun including a housing, an external anode attached to an exterior surface of said housing, a cathode extending through said housing, and an arc generator for generating an electric arc between the anode and cathode; said anode and said cathode being spaced from said portion of said component being coated; a nozzle for emitting arc gas into the electric arc, the electric arc being operable for ionizing the gas to create a plasma gas stream; and a powder injector for injecting a powdered material selected from the group consisting of copper, nickel, aluminum-copper alloy and copper nickel, into the plasma gas stream; wherein said cathode includes an electrode extending therefrom and disposed through an aperture of said nozzle of said microplasma gun, and said anode is disposed within an anode holder mounted to said exterior surface of said microplasma gun and aligned opposite said nozzle, and wherein said powder injector comprises a hopper containing said powdered material, said hopper is located externally of said housing, and a chute for injecting said powdered material into said plasma gas stream, said chute having a valve positioned therein for controlling a feed rate of said powdered material into the plasma gas stream.