THERMALLY ADAPTIVE SURFACES FOR RECEIVING THERMAL SPRAYS

1 . A method of applying thermal spray particles to a composite, wherein said method includes the steps of providing a composite that includes a thermally sensitive surface, and applying the thermal spray particles at a temperature that is high enough to cause a temperature-dependent change in the thermally sensitive surface of the composite, wherein the temperature-dependent change improves adhesion between the thermal spay particles and the composite.

2 . The method as claimed in claim 1 , wherein said composite includes in a least a surface portion thereof, low temperature material within the composite that irreversibly changes when subjected to the thermal spray particles at a high temperature.

3 . The method as claimed in claim 2 , wherein said low temperature material includes low temperature fibers.

4 . The method as claimed in claim 3 , wherein said low temperature fibers are cotton fibers.

5 . The method as claimed in claim 2 , wherein the irreversible change involves providing pores having diameters of about 1 μm to 1 mm.

6 . The method as claimed in claim 1 , wherein said composite includes in at least a surface portion thereof, a low temperature resin material that softens when subjected to the thermal spray particles at a high temperature.

7 . The method as claimed in claim 6 , wherein said low temperature resin material includes rubber compound.

8 . The method as claimed in claim 1 , wherein said composite has a hardness of about 10-50 HRB.

9 . The method as claimed in claim 1 , wherein said composite has a hardness of about 20-35 HRB.

10 . The method as claimed in claim 1 , wherein said method further includes the steps of permitting the thermal spray particles to form a first layer, and applying further thermal spray particles to form a second layer of thermal spray particles.

11 . The method as claimed in claim 1 , wherein the temperature is below about 500° C.

12 . A composite material including an outer surface that is adapted to receive a thermal spray, said outer surface having hardness of less than about 50 HRB and being adapted to absorb a sufficient amount of impact from particles at high velocity from the thermal spray such that the particles adhere to the surface.

13 . The composite material as claimed in claim 12 , wherein said composite material has a hardness of about 10-50 HRB.

14 . The composite material as claimed in claim 12 , wherein said composite material has a hardness of about 20-35 HRB.

15 . The composite material as claimed in claim 12 , wherein said composite material includes low temperature filler that become at least partially destroyed at temperatures below about 450C thereby leaving open pores within the composite material.

16 . The composite material as claimed in claim 12 , wherein said low temperature filler includes fibers.

17 . The composite material as claimed in claim 16 , wherein said fibers are cotton fibers.

18 . The composite material as claimed in claim 12 , wherein said composite material includes thermoplastic resin that at least partially softens under heat of the thermal spray particles to absorb an impact of thermal spray particles on a surface of the composite material.

19 . The composite material as claimed in claim 12 , wherein said composite material includes rubber that at least partially softens under heat of the thermal spray particles to absorb an impact of thermal spray particles on a surface of the composite material.

20 . The composite material as claimed in claim 12 , wherein the outer surface of said composite is non-planar.

21 . The composite material as claimed in claim 12 , wherein the outer surface of said composite is planar.

22 . The composite material as claimed in claim 12 , wherein said composite is a doctor blade for use in a papermaking machine.