Thermal Spraying Torch Localized Adhesion Control
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Solution Overview
Problem
The formation of thermal sprayed coatings is compromised by molten particles adhering to the thermal spraying torch, leading to a decrease in coating quality due to the mixing of coating deposits with the newly-discharged particles.
Innovation Solution
The thermal spraying torch features a discharge port periphery with a rough surface that easily adheres to molten particles, while the external surface has a smooth, copper cover that minimizes adhesion, preventing the deposition and separation of coating deposits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thermal spraying torch has a uniform surface that easily adheres to molten material, then primary particles can adhere strongly to prevent coating deposit separation, but secondary particles with low adhesion strength will also adhere and form coating deposits that decrease quality
Solution Approach 1:
The patent applies different surface properties to different regions of the thermal spraying torch. The discharge port periphery has a surface that easily adheres to molten material (high adhesion), while the external surface has a surface that resists adhesion (low adhesion). This local differentiation allows primary particles to adhere strongly at the discharge port while preventing secondary particles from adhering to the external surface, thus resolving the contradiction between adhesion strength and coating quality.
2Manufacturing precision
If the thermal spraying torch surface is made smooth to prevent adhesion of secondary particles, then coating deposit formation is reduced, but primary particles with high adhesion strength will not adhere properly and will separate as coating deposits
Solution Approach 1:
The patent implements local quality by creating distinct surface regions: the discharge port periphery maintains a surface that promotes strong adhesion for primary particles, while the external surface is made smooth or has low adhesion properties to prevent secondary particle adhesion. This spatial differentiation of surface properties simultaneously achieves both high adhesion strength where needed and reduced coating deposit formation where not needed.
3Reliability
If the thermal spraying torch surface is made rough to enhance adhesion of molten material, then coating deposit separation is suppressed, but secondary particles will also adhere and mix into the thermal spraying flame decreasing coating quality
Solution Approach 1:
The patent resolves this contradiction by applying rough or high-adhesion surface treatment only to the discharge port periphery where primary particles are discharged, while keeping the external surface smooth or low-adhesion. This localized application of surface treatment ensures that the benefits of enhanced adhesion (suppression of coating deposit separation) are confined to the discharge port region, while the external surface remains free from secondary particle adhesion, thus maintaining coating quality.
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 effectively suppresses the adhesion and separation of coating deposits on the torch, maintaining coating quality by ensuring primary particles adhere strongly to the discharge port and secondary particles with low adhesion strength are prevented from adhering to the external surface.
Implementation Method 1
a discharge port periphery includes a section to which a molten material adheres more easily
Implementation Method 2
an external surface includes a section to which the molten material adheres less easily than to the discharge port periphery
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A thermal spraying torch (1) includes: a discharge port (17) configured to discharge a molten material; a discharge port periphery (23b) located on a peripheral edge of the discharge port (17) on a front side in a discharge direction of the molten material and extending in the discharge direction; and an external surface (13a) continuous with a front end of the discharge port periphery (23b). The discharge port periphery (23b) includes a section to which the molten material adheres more easily than to the external surface (13a) and the external surface (13a) includes a section to which the molten material adheres less easily than to the discharge port periphery (23b).