Wire-arc spraying of a zinc-nickel coating

Abstract

A zinc-nickel substrate is applied to a component by using a zinc-nickel wire formed with between about 8 to 20 percent nickel and between about 80 to 90 percent zinc. This formed zinc-nickel wire is held in a two wire electric arc spray system to spray the zinc-nickel substrate on the component, such as an aircraft part, while operating the two wire electric arc spray system within a specific range of operating parameters.

1 . A zinc-nickel wire for use as an electrode in a two wire electric arc spray system comprised of: 
 from between about 8 to about 20 percent nickel and from between about 80 to 92 percent zinc.    
   
   
       2 . The zinc-nickel wire of  claim 1  wherein the zinc-nickel wire is formed from an elongated zinc wire with nickel electroplated around the elongated zinc wire to a thickness that achieves a desired zinc-nickel wire composition.  
   
   
       3 . The zinc-nickel wire of  claim 2  wherein the concentration of nickel in the zinc-nickel wire is between about 10 to 12 percent and the concentration of zinc is between about 88 to 90 percent.  
   
   
       4 . The zinc-nickel wire of  claim 3  wherein the concentration of nickel in the zinc-nickel wire is about 10 percent and the concentration of zinc is about 90 percent.  
   
   
       5 . The zinc-nickel wire of  claim 1  wherein the zinc-nickel wire is formed from a cored wire having a tubular zinc sheath with a nickel powder in the core.  
   
   
       6 . The zinc-nickel wire of  claim 5  wherein the concentration of nickel in the zinc-nickel wire is between about 10 to 12 percent and the concentration of zinc is between about 88 to 90 percent.  
   
   
       7 . The zinc-nickel wire of  claim 1  wherein the zinc-nickel wire is formed from a zinc-nickel alloy melt that is drawn to a final desired diameter.  
   
   
       8 . The zinc-nickel wire of  claim 7  wherein the concentration of nickel in the zinc-nickel wire is between about 10 to 12 percent and the concentration of zinc is between about 90 to 88 percent.  
   
   
       9 . A method of forming a zinc-nickel substrate on a component comprising the steps of: 
 utilizing a two wire electric arc spray system to spray zinc-nickel on the component;    inserting zinc-nickel wire in the two wire electric spray system as electrodes;    operating the two wire electric spray system within a specific range of operating parameters; and    forming the zinc-nickel wire from between about 8 to about 20 percent nickel and from between about 80 to 92 percent zinc.    
   
   
       10 . The method of  claim 9  wherein the two wire electric spray system is operated between about 24 to 36 volts, while maintaining between about 80 to 200 amperes with pressurized atomizing air maintained at between about 80 to 120 psig.  
   
   
       11 . The method of  claim 10  wherein the two wire electric spray system is operated at about 30 volts and about 120 amperes, with the atomizing air pressure at about 100 psig.  
   
   
       12 . The method of  claim 11  wherein the zinc-nickel wire is formed from an elongated zinc wire with nickel electroplated around the elongated zinc wire to a thickness that achieves a desired zinc-nickel wire composition.  
   
   
       13 . The method of  claim 12  wherein the concentration of nickel in the zinc-nickel wire is about 10 percent and the concentration of zinc is about 90 percent.  
   
   
       14 . The method of  claim 11  wherein the zinc-nickel wire is formed from a cored wire having a tubular zinc sheath with a nickel powder in the core.  
   
   
       15 . The method of  claim 11  wherein the zinc-nickel wire is formed from a zinc-nickel alloy melt that is drawn to a final desired diameter.  
   
   
       16 . A zinc-nickel wire for use as an electrode in a two wire electric arc spray system comprised of: 
 from about 10 percent nickel and from about 90 percent zinc.    
   
   
       17 . The zinc-nickel wire of  claim 16  wherein the zinc-nickel wire is formed from an elongated zinc wire with nickel electroplated around the elongated zinc wire to a thickness that achieves a desired zinc-nickel wire composition.  
   
   
       18 . The zinc-nickel wire of  claim 16  wherein the zinc-nickel wire is formed from a zinc-nickel alloy melt that is drawn to a final desired diameter.  
   
   
       19 . The zinc-nickel wire of  claim 16  wherein the zinc-nickel wire is formed from a cored wire having a tubular zinc sheath with a nickel powder in the core.