Plasma spraying system with adjustable coating medium nozzle

Abstract

A plasma spraying system is provided for coating a substrate. The plasma spraying system includes a plasma gun, a nozzle and a mounting system. The plasma gun is adapted to direct plasma towards the substrate. The nozzle is adapted to direct coating medium into the plasma. The mounting system is adapted to rotate the nozzle to change an angle of incidence between the coating medium and the plasma.

What is claimed is: 
     
         1 . A process for plasma spraying a substrate, the process comprising:
 directing plasma from a plasma gun towards the substrate;   directing coating medium from a nozzle into the plasma; and   rotating the nozzle to change an angle of incidence between the coating material and the plasma.   
     
     
         2 . The process of  claim 1 , wherein the coating medium comprises a suspension of coating particles within a carrier liquid. 
     
     
         3 . The process of  claim 1 , wherein the nozzle is rotated before the plasma is directed from the plasma gun. 
     
     
         4 . The process of  claim 1 , wherein the nozzle is rotated while the plasma is being directed from the plasma gun. 
     
     
         5 . The process of  claim 1 , further comprising moving the nozzle along an axis to change a distance between the nozzle and the plasma gun. 
     
     
         6 . The process of  claim 1 , further comprising rotating the nozzle at least partially circumferentially around the plasma gun. 
     
     
         7 . A plasma spraying system for coating a substrate, the system comprising:
 a plasma gun adapted to direct plasma towards the substrate;   a nozzle adapted to direct coating medium into the plasma, the coating medium comprising dry coating particles; and   a mounting system adapted to rotate the nozzle to change an angle of incidence between the coating medium and the plasma.