Plasma spray apparatus integrating water cleaning

Abstract

An integrated apparatus and method comprises a plasma gun with a water supply, treatment fluid supply, and controls, the combination of which is adapted for directing a plume onto a surface of a three-dimensional part to treat the surface; and for controlling injection of water into the plume with the plume directed onto an adjacent surface to clean debris and undesired material from the adjacent surface; and for subsequently directing the plume (without water) onto the adjacent surface to treat the adjacent surface. The apparatus and method are particularly useful in suspension plasma spray systems, but are not believed to be limited to that.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuing application of U.S. patent application Ser. No. 13 / 826,252, filed Mar. 14, 2013, entitled “PLASMA SPRAY APPARATUS INTEGRATING WATER CLEANING,” which claims benefit and priority to U.S. Provisional Patent Application No. 61 / 639,471 filed Apr. 27, 2012, entitled PLASMA SPRAY APPARATUS INTEGRATING WATER CLEANING, the entire contents of which are incorporated herein.BACKGROUND[0002]The present invention relates to plasma spray apparatus, and more particularly relates to a plasma spray apparatus integrating water cleaning of contaminants and overspray.[0003]Plasma spray coatings adhere to a substrate primarily by mechanical forces. Thus, for optimal coating performance, loose debris such as grit blasting residue remaining from surface preparation or overspray generated during a coating process should be removed from the substrate prior to applying a coating. Otherwise, the applied coating has poor adhesion and ...

AI Technical Summary

Benefits of technology

The present invention relates to a plasma spray surface treatment apparatus and an integrated method of plasma treating process. The apparatus includes a plasma gun, a water supply, and a water line for transferring water into the plume. The treatment fluid includes a suspension. The method includes injecting water into the plume of the plasma gun for cleaning debris and undesirable particles from the surface. The plume can be directed onto a three-dimensional part for treating the surface. The method can also simultaneously coat and clean using a thermal spray process by injecting suspension into the plume top and water under a significantly lower pressure into the plume bottom, wherein minimal interaction occurs between the injected species.

Problems solved by technology

Otherwise, the applied coating has poor adhesion and will spall or flake off.

Additionally, the grit-blasting process leaves dust particulates on the substrate surface that needs to be removed prior to applying a coating.

Instead, separate equipment is typically used, resulting in additional capital expenditure for equipment, additional maintenance, and a less efficient process flow since the plasma torch / treating process must be shut off (or redirected) while separate equipment is used to clean loosely adhered particulates.

In some existing processes, a person or robot may enter into a work area to clean loosely adhered particulates, which can result in possible introduction of contaminants and process inconsistencies.

A reason the plasma jet alone is not used to blow loosely adhered particulates off a substrate is because the heat from the plasma can partially melt these particulates, causing an increase in adhesion of the undesirable material to the substrate, making it more difficult to remove the undesirable material.

Also, even though the adhesion of the undesirable material is increased, the adhering strength may still be much lower strength than is necessary for good coating adhesion.

Also, the undesirable material is unlikely to be in the proper form (e.g. phase or morphology) for a good coating.

Similarly, a plasma torch is not used to propel blasting media at a substrate because the media would melt and form a coating on the substrate rather than clean it.

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