Suspension Plasma Spray Apparatus and Use Methods
A plasma spray gun has: a plasma outlet having an axis; and a plurality of liquid feedstock outlets having a non-uniform distribution about said axis.
1 . A plasma spray gun comprising:
a plasma outlet having an axis; and
a plurality of liquid feedstock outlets having a non-uniform distribution about said axis.
2 . The plasma spray gun of claim 1 wherein:
the plurality of liquid feedstock outlets have a distribution that averages off the axis.
3 . The plasma spray gun of claim 1 wherein:
the plurality of liquid feedstock outlets have a distribution that averages along the axis.
4 . The plasma spray gun of claim 1 wherein:
the plurality of liquid feedstock outlets are each configured to dispense a suspension in a direction toward the axis.
5 . The plasma spray gun of claim 1 wherein:
the plurality of liquid feedstock outlets comprises a pair of liquid feedstock outlets spaced by a nonzero angle of less than 45° about said axis.
6 . The plasma spray gun of claim 5 wherein:
the pair of liquid feedstock outlets are formed by respective orifice pieces mounted in a shared body.
7 . The plasma spray gun of claim 5 wherein:
the pair of liquid feedstock outlets have respective axes intersecting beyond the plasma outlet axis.
8 . The plasma spray gun of claim 5 wherein:
the pair of liquid feedstock outlets have respective axes at an angle to each other smaller than said nonzero angle when viewed parallel to the axis.
9 . The plasma spray gun of claim 5 wherein:
the pair of liquid feedstock outlets are at a single axial position relative to the plasma outlet.
10 . The plasma spray gun of claim 5 wherein:
the pair is a first pair; and
the plasma spray gun further comprises a second pair of liquid feedstock outlets wherein each liquid feedstock outlet of the second pair is diametrically opposite a corresponding liquid feedstock outlet of the first pair.
11 . The plasma spray gun of claim 10 wherein:
the only liquid feedstock outlets are the first pair and the second pair.
12 . The plasma spray gun of claim 5 wherein:
the angle is 10° to 45°.
13 . The plasma spray gun of claim 5 wherein:
the angle is 20° to 35°.
14 . The plasma spray gun of claim 5 wherein:
the only liquid feedstock outlets are the pair.
15 . The plasma spray gun of claim 5 further comprising a third liquid feedstock outlet a nonzero angle from the pair of liquid feedstock outlets.
16 . A plasma spray apparatus including the plasma spray gun of claim 1 and further comprising:
a suspension or solution line coupled to the plasma spray gun;
a suspension or solution supply coupled to the suspension or solution supply line;
a carrier gas supply coupled to the plasma spray gun; and
a power line coupled to the plasma spray gun.
17 . A method for using the plasma spray gun of claim 1 , the method comprising:
discharging a plasma from the plasma spray gun; and
discharging suspension or solution flows from the plurality of liquid feedstock outlets to intersect the plasma.
18 . The method of claim 17 used to apply a coating to a part wherein:
the part comprises a nickel-based superalloy substrate.
19 . The method of claim 17 used to apply a coating to a part wherein:
the part is a gas turbine engine component.
20 . The method of claim 17 used to apply a coating to a part wherein:
the coating is a stabilized zirconia.
21 . A plasma spray method using a plasma spray gun, the method comprising:
discharging a plasma from a plasma outlet; and
discharging a pair of liquid feedstock streams from a pair of liquid feedstock outlets, the liquid feedstock streams having a non-uniform distribution about an axis of the plasma.