Thermal Spray Coating Apparatus and Method of Use

Abstract

This invention discloses a metal coating method whereby an abrasion resistant and wear resistant coating is first applied to the that portion of a metal object of extended size to be protected, the coating is then fused onto the metal object with the use of a temperature controlled induction heater, which results in a metal object, at least a portion of which is more abrasion resistant and wear resistant than the uncoated metal object.

What is claimed: 
     
         1 . A thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives;
 the torch system comprises a pair of torches, that being a first torch and a second torch, a plurality of gas cylinders, a plurality of connections to connect the plurality of gas cylinders to the pair of torches, a control mechanism to activate and deactivate the flow of the gases to the torches and to activate the thermal spray coating apparatus, an attachment to connect the first torch to the coating feed system, and a plurality of guides;   the rack system comprises a frame, a structure to hold the pair of torches and allow the proper positioning of the torches while a compound is applied to the metal object, a plurality of attachments that hold and allow the metal object to be manipulated during the coating process, and a plurality of drives that are attached to the structure that hold the pair of torches and facilitate the manipulation of the pair of torches past the metal object; and   the coating feed system comprises a coating storage container, and the attachment from the coating storage container to the first torch such that, when the torches are activated the compound flows from the coating storage container, through the attachment, to the first torch, enters the flow of the gas from the plurality of gas cylinders, whereupon, the compound is applied onto the metal object as the first torch also heats the metal object.   
     
     
         2 . A thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives;
 the torch system comprises a pair of torches, that being a first torch and a second torch, a plurality of gas cylinders, a plurality of connections to connect the plurality of gas cylinders to the pair of torches, a control mechanism to activate and deactivate the flow of the gases to the torches and to activate the thermal spray coating apparatus, an attachment to connect the first torch to the coating feed system, and a plurality of guides;   the rack system comprises a frame, a structure to hold the pair of torches and allow the proper positioning of the torches while the compound is applied to the metal object, a plurality of attachments that hold and allow the metal object to be manipulated during the coating process, and a plurality of drives that are attached to the plurality of attachments and facilitate the manipulation of the metal object past the pair of torches; and   the coating feed system comprises a coating storage container, and an atttachment from the coating storage container to the first torch such that, when the torches are activated the compound flows from the coating storage container through the attachment to the first torch, enters the flow of the gas from the plurality of gas cylinders, whereupon, the compound is applied onto the metal object as the first torch also heats the metal object.   
     
     
         3 . A thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives;
 the torch system comprises a pair of torches, that being a first torch and a second torch, a plurality of gas cylinders, a plurality of connections to connect the plurality of gas cylinders to the pair of torches, a control mechanism to activate and deactivate the flow of the gases to the torches and to activate the thermal spray coating apparatus, attachments to connect the first torch to the coating feed system, and a plurality of guides;   the rack system comprises a frame, a structure to hold the pair of torches and allow the proper positioning of the torches during the coating of the metal object, a plurality of attachments that hold and allow the metal object to be manipulated during the coating process, and a plurality of drives that are attached to the structure that hold the pair of torches, attached to the plurality of attachments, and facilitate the manipulation of the metal object and the manipulation of the structure that holds the pair of torches during the application of the compound to the metal object; and   the coating feed system comprises a coating storage container, and an attachment from the coating storage container to the first torch such that, when the torches are activated the compound flows from the coating storage container, through the attachment, to the first torch, enters the flow of the gas from the plurality of gas cylinders, whereupon, the compound is applied onto the metal object as the first torch also heats the metal object.   
     
     
         4 . A method of operation of a thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object, wherein the thermal spray coating apparatus comprises a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives, the method of operation comprising:
 first, cleaning the metal object, to remove rust, dirt and other foreign material from the surface of the metal object;   second, the metal object is attached to the rack system with the use of a plurality of attachments;   third, a pair of torches of the torch system, that being a first torch and a second torch, are positioned relative to the metal object;   fourth, the plurality of guides are positioned;   fifth, the thermal spray coating apparatus is activated to begin the operation of coating the metal object;   during operation the plurality of drives facilitate the movement for the metal object to be coated;   also during operation, the first torch sprays a compound derived from the coating feed system onto the metal object and heats the compound and metal object to begin the process of adhering the compound onto the metal object and the second torch, which follows behind the first torch, continues to heat the compound and the metal object to complete the adhering process; and   sixth, once the plurality of guides reach a designated position relative to the metal object the thermal spray coating apparatus is deactivated.   
     
     
         5 . The method of operation of the thermal spray coating apparatus of  claim 4  wherein, during the operation of the thermal spray coating apparatus, the metal object is moved past the pair of torches. 
     
     
         6 . The method of operation of the thermal spray coating apparatus of  claim 4  wherein, during the operation of the thermal spray coating apparatus, the pair of torches may be moved past the metal object. 
     
     
         7 . The method of operation of the thermal spray coating apparatus of  claim 4  wherein, during the operation of the thermal spray coating apparatus, the metal object may be manipulated while the pair of torches also progresses.