Rotatable Thermal Spray Contact Tips for Continuous Wire Atomization

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Solution Overview

Problem

Conventional thermal spray systems experience significant downtime due to maintenance and repairs, particularly when applying metal cladding to large substrates in situ, as contact tips wear down and require replacement, leading to misalignment and poor atomization, which affects the quality and efficiency of the cladding process.

Innovation Solution

The apparatus and system feature adjustable contact tips that can be manually or automatically rotated to provide new wear surfaces without disassembly, ensuring continuous operation and maintaining alignment of feedstock wires for effective atomization, while not obstructing high-velocity gas flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional contact tips are used in thermal spray systems, then the initial alignment and atomization quality are good, but the contact tips wear down over time requiring replacement and causing downtime

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidmaintenance downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The contact tip is designed with multiple grooves arranged circumferentially, allowing it to be rotated to different angular positions. This dynamic reconfiguration enables the system to switch between multiple wear surfaces on the same contact tip, extending its service life and eliminating the need for frequent replacements that cause downtime.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The contact tip is pre-designed with multiple grooves at different angular positions before operation begins. When wear occurs on one groove, the contact tip can be rotated to present a fresh, unworn groove to the wire feed, allowing immediate continuation of operation without waiting for maintenance or replacement.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If contact tips are frequently replaced to maintain alignment, then atomization quality is preserved, but production efficiency decreases due to maintenance interruptions

Engineering Contradiction:

Improvewire alignment precisionVSAvoidcladding application rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The rotatable contact tip design allows operators to dynamically adjust the angular position to maintain optimal wire alignment without replacing the contact tip. This preserves manufacturing precision while avoiding production interruptions, as the same contact tip can be repositioned multiple times during extended operation periods.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

By providing multiple grooves on a single contact tip that can be sequentially used, the system maintains continuous useful action. The contact tip remains in place throughout operation, and when one groove wears, the tip is simply rotated to engage a fresh groove, ensuring uninterrupted wire feeding and cladding application.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of repair

If contact tips are made more durable to reduce replacement frequency, then maintenance costs decrease, but the initial cost of the contact tip system increases

Engineering Contradiction:

Improvemaintenance frequencyVSAvoidcontact tip structure

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The contact tip is segmented into multiple functional grooves, each capable of independent use. This segmentation allows the single contact tip component to perform the function of multiple contact tips, reducing the frequency of replacements needed while keeping the overall device structure relatively simple and manageable.

Inventive Principle:

Principle #1Segmentation

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

This design reduces downtime, enhances the quality and speed of the cladding process, and improves the uniformity of the applied coating by maintaining consistent wire alignment and atomization characteristics, thus increasing production efficiency and reducing maintenance costs.

Implementation Method 1

The first contact tip and the second contact tip are configured to contact and deflect a wire towards the nozzle

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

The apparatus includes a high-velocity gas system

Methodology Applied

Scientific EffectGas Flow:

Implementation Method 3

The first electrode and the second electrode are configured to apply a current to melt the wire at a contact point

Methodology Applied

Scientific EffectJoule Heating: Joule Heating

Data Source

PatentUS12516408B2Apparatus and system for thermal spray and related methods thereof

Publication Date: 2026.01.06 INTEGRATED GLOBAL SERVICES INC

AI summary

This disclosure provides an apparatus, system, and method for thermal spraying a metal cladding on a substrate. The apparatus may include a housing having a first electrode and a second electrode disposed in the housing. The second electrode can be spaced apart from the first electrode. The apparatus includes a first contact tip removably attached to the first electrode and a second contact tip removably attached to the second electrode. The position of the first contact tip and second contact tip is configured to be selectively adjusted on the first electrode and the second electrode to provide a plurality of contact surfaces for a feedstock wire. The apparatus includes a nozzle between the first contact tip and the second contact tip. The first contact tip and the second contact tip are configured to contact and deflect a wire towards the nozzle.