Copper-Plated Stainless Thermal Spray Wire for Stable Arc Feed
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Solution Overview
Problem
Existing thermal spray wires for continuous arc wire thermal spraying machines lack sufficient electrical conductivity and stable voltage, leading to unstable arc thermal spraying.
Innovation Solution
A stainless steel thermal spray wire with a chromium content of 8-20% by mass, including carbon, nickel, and manganese, and a copper-plated coating of 0.3-1.2 µm thickness, electrolytically plated under specific conditions, is used to ensure stable and efficient arc thermal spraying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stainless steel thermal spray wire is used to provide corrosion resistance, then corrosion resistance is improved, but electrical conductivity deteriorates
Solution Approach 1:
The patent applies composite material structure by combining stainless steel core (providing corrosion resistance) with copper coating (providing electrical conductivity). The copper layer is electrolytically plated on the stainless steel wire surface, creating a composite structure that simultaneously achieves both corrosion resistance from the stainless steel base and sufficient electrical conductivity from the copper coating for stable arc thermal spraying.
2Use of energy by moving object
If copper plating is applied to improve electrical conductivity, then electrical conductivity is improved, but wire feedability deteriorates due to plating debris
Solution Approach 1:
The patent optimizes the copper plating thickness parameter to 0.3-1.2 µm through electrolytic plating process control. This specific thickness range provides sufficient electrical conductivity for stable arc thermal spraying while minimizing plating debris generation that would interfere with wire feeding. The controlled parameter ensures both electrical performance and operational smoothness.
3Reliability
If chromium content is increased to improve corrosion resistance, then corrosion resistance is improved, but wire strength deteriorates due to excessive softness
Solution Approach 1:
The patent optimizes the chromium content parameter to 8-20% by mass in the stainless steel composition. This controlled chromium range provides adequate corrosion resistance for thermal spray applications while preventing excessive softness that would compromise wire strength and feedability. The parameter optimization balances corrosion protection with mechanical integrity.
Solution Approach 2:
The patent creates a composite material system where stainless steel (with optimized Cr content) provides corrosion resistance and structural strength, while copper coating provides electrical conductivity. This composite approach allows the stainless steel core to maintain optimal chromium levels for corrosion protection without sacrificing wire strength, as the copper layer handles the electrical function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The thermal spray wire provides sufficient electrical conductivity and favorable wire feedability, enabling continuous and stable arc thermal spraying at a stable voltage, preventing wire breakage and improving coating strength and adhesion.
Implementation Method 1
a copper-plated coating of 0.3-1.2 µm thickness, electrolytically plated under specific conditions
Implementation Method 2
application of a voltage generates an electric arc between two wire-like thermal spray materials. As a result, wire tips are melted off
Data Source
AI summary
Provided is a thermal spray wire as a thermal spray material for use in continuous arc wire thermal spraying machines, the thermal spray wire being for performing continuous and stable arc thermal spraying with sufficient electrical conductivity and at a stable voltage. The thermal spray wire includes a copper-plated coating having a thickness of from 0.3 to 1.2 µm on a surface of a rod made of stainless steel. Using the thermal spray wire allows for stable arc thermal spraying by a continuous arc thermal spraying machine including a wire feeding mechanism.