Wire-Like Product with Composite Core and Process for Producing the Same

Abstract

A wire-like product (10) for use as a feedstock in metal or plasma spraying or welding includes a metal case (12) and a composite core (14) in the case, with the core being partially sintered and containing enough metal to conduct an electrical current. To form the wire-like product, a metal tubular segment (20) is filled with a powder (26) in the absence of oxygen. Then the tubular segment is reduced in cross-section to compact the powder within it. Next the tubular segment is heated to anneal it and effect a partial sinter (32) of the powder. Another reduction in cross section breaks the partial sinter into particles and further compacts them, whereas a further heating anneals the tubular segment and resinters the particles. Repetitions of the cycle produce the wire-like product.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application derives and claims priority from U.S. provisional application 60 / 871,310, filed 21 Dec. 2006, which is incorporated herein by reference.TECHNICAL FIELD[0002]This invention relates in general to wire-like products and more particularly to a wire-like product having a metallic case and a composite core and to a process for producing the same. The core constitutes a thermo-mechanically bonded, semimetallic, composite and is contained within a malleable and ductile case, thus producing a quasicomposite wire-like product.BACKGROUND ART[0003]Certain manufacturing processes require weld overlays and thermal spray coatings of very specific composition that are applied by melting a feedstock and depositing it on the surface of a substrate. For example, by means of thermal spraying, a steel substrate may be provided with a corrosion-resistant coating of nickel and other constituents, even nonmetal constituents. Indeed, many thermal...

AI Technical Summary

Problems solved by technology

Moreover, the powder of the core, being loosely compacted, does not in a heat source, such as a combustion flame or an arc, mix well with the material of the case, thus detracting from the uniformity and integrity of the deposit.

Also, a loosely compacted core will not conduct electricity well, if at all, so an arc will attach much more readily to the metal case than to the powder core.

This renders the arc less stable and detracts from the quality of the coating.

Apart from that, wires that are formed entirely from alloys have limitations as to their constituent components.

Images