Swirling Wire Arc Spray for Aircraft Deck Coatings
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Solution Overview
Problem
There is a need for a sustainable, heat-resistant, non-skid coating system for vertical lift jet aircraft decks that provides corrosion protection, long-term durability, and high bond strength on various steel types, which existing technologies have not adequately addressed.
Innovation Solution
A thermal spray system using a twin wire arc spray method with a ceramic-filled hollow aluminum or zinc wire, applied in a swirling pattern by a multi-head metal spray system mounted on a two-axis robot, which reduces peak heat load and enhances adhesion to steel substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional thermal spraying is used on steel decks, then coating application is possible, but heat resistance and adhesion at high temperatures are insufficient
Solution Approach 1:
The patent applies composite materials by combining zinc metal with ceramic particles (such as alumina, silica, or magnesia) to create a composite coating material. This composite structure provides both heat resistance from the ceramic phase and adhesion to steel substrate from the zinc matrix, resolving the contradiction between heat resistance and adhesion at high temperatures.
Solution Approach 2:
The patent changes the chemical composition parameters of the coating material by incorporating specific ratios of zinc (5-40 wt%), ceramic particles (60-90 wt%), and optional alloying elements. These parameter changes enable the coating to maintain adhesion properties while withstanding high temperatures up to 1000°C or higher.
2Duration of action of stationary object
If existing coating systems are applied to aircraft carrier decks, then surface coverage is achieved, but durability under extreme heat and wear is inadequate
Solution Approach 1:
The composite coating material consisting of zinc bound with ceramic particles provides enhanced durability by combining the protective properties of zinc (corrosion resistance, adhesion) with the thermal stability and wear resistance of ceramics. This composite structure enables the coating to withstand extreme conditions on aircraft carrier decks including jet exhaust heat, mechanical wear from aircraft operations, and corrosive marine environments.
Solution Approach 2:
The patent applies local quality by distributing ceramic particles throughout the zinc matrix to create regions with different properties - the zinc provides adhesion and corrosion resistance while embedded ceramic particles provide localized heat resistance and wear protection. This heterogeneous structure optimizes performance across different functional requirements.
3Productivity
If standard wire arc spray is used, then coating application is efficient, but bond strength on various steel types is insufficient
Solution Approach 1:
The patent modifies the wire composition parameters by creating a hollow wire structure filled with ceramic particles, changing the material parameters from pure metal to composite. This parameter change enables the wire arc spray process to deposit composite material that achieves strong bond strength (exceeding 1000 psi) on various steel types while maintaining the efficiency of automated wire feed spraying.
Solution Approach 2:
The patent replaces simple metal wire with a composite wire structure that incorporates ceramic particles within the metal matrix. This substitution transforms the coating material from a purely metallic system to a composite system, enabling enhanced bond strength through the synergistic combination of zinc adhesion properties and ceramic reinforcement while maintaining wire arc spray processing efficiency.
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 system produces a durable, heat-resistant non-skid coating with improved adhesion and reduced heat input, suitable for high-temperature applications on steel decks, such as aircraft carriers, with enhanced bonding and durability.
Implementation Method 1
An electric arc generated between the ends of the wires causes the wires to melt in the region of the arc
Implementation Method 2
a plurality of pressurized gas streams are directed toward the electrical arc to atomize, cool, and uniformly distribute the molten metal
Data Source
AI summary
A wire arc spray system (100) includes a plurality of arc spray subsystems (130) mounted to a movable carriage (120) on an x-y robot (110). Each arc spray subsystem includes a wire drive (132) that provides wire (133, 134) to a spray head (138) through a pair of lead cables (136). The spray heads are mounted for circular motion, such that the molten spray is applied to an underlying substrate in a swirling pattern. In one embodiment, the spray heads are mounted to a distal end of a rod (164) that extends through a swivel ball joint (166) and engages an eccentric link (162) fixed to a motor (160). The system applies an overlapping pattern of molten spray to provide excellent non-skid and adhesion properties. The system is particularly suited to spray coating with a wire comprising a hollow metallic portion and a core having ceramic particles.