David Russell Hawley

7030336, Apr 18, 2006

Dec 11, 2003

10/731986

David Hawley - Kings Park NY, US

Sulzer Metco (US) Inc. - Westbury NY

B23K 10/00

21912151, 21912152, 21912149, 219 75

An improved anode element for a plasma generator is comprised of an anode body having a central bore therein. A plurality of arc attachment regions are formed along a surface of the central bore. Each attachment is configured to provide a substantially radially predefined attachment point for an electrical arc extending between the attachment region and a respective cathode when the anode element is used in a plasma generator. The arc attachment points can be areas along the central bore which are elevated or proud relative to adjacent areas. The attachment points can also be defined at least in part by asymmetrical cooling of the anode.

7482035, Jan 27, 2009

Apr 28, 2004

10/835358

Richard K. Schmid - Melville NY, US
Arno Refke - Mellingen, CH
Gerard Barbezat - Opfikon, CH
David Hawley - Kings Park NY, US

Sulzer Metco AG - Wohlen

C23C 14/54

427 10, 427571, 427579, 427294

A method of coating a substrate by thermal application of the coating materials using a plasma jet is disclosed. The properties of the plasma jet are determined by controllable process parameters. The coating material and a process gas mixture are injected into the plasma jet where the coating material is partly or completely evaporated depending on the controllable parameters. The phases of the coating material present in vapor and, optionally, condensed form are at least partly deposited on the substrate. A diagnostic measuring method determines the relative proportion of vapor and/or condensed phase for the coating material transported in the plasma jet. The controllable process parameters are set with respect to desired values using such measured data. Regulation of direct manufacture of the coating, particularly a multi-layer coating system, is carried out with respect to these desired values, which correspond to a predetermined vapor or condensed phase proportion.

7582846, Sep 1, 2009

Dec 21, 2006

11/642651

Ronald J. Molz - Mt. Kisco NY, US
David Hawley - Kings Park NY, US
Richard McCullough - Westbury NY, US

Sulzer Metco (US), Inc. - Westbury NY

B23K 10/00

21912147, 219 7616, 21912148, 118715

The present invention provides a method and apparatus of producing a dense coating with desirable stress conditions similar to coatings produced by a cold spray processes, but with higher process efficiencies and lower gas consumption. The inventive process combines features of a plasma process method of gas heating and a cold spray process to accelerate the gas, incorporating these elements into a single hybrid process.

7759599, Jul 20, 2010

Mar 30, 2006

11/392650

David Hawley - Kings Park NY, US
Ronald J. Molz - Mt. Kisco NY, US

Sulzer Metco (US), Inc. - Westbury NY

B23K 10/00

21912147, 21912148, 2191215, 219 75, 31323131

The present invention provides a standard interface for providing mechanical location, mechanical orientation, electrical connections, and water chamber seals for the exchange of a variety of plasma forming nozzles each associated with a specific plasma plume characteristic. The flexibility of the nozzle attachment is improved over prior designs by providing a standard exterior nozzle configuration and nozzle clamping assembly on the plasma gun so that multiple nozzles configurations (giving different plasma flow properties) can easily be used with the same devices. The joining of the nozzle to the receptacle forms a channel for cooling liquid to flow from the plasma gun through the nozzle to a return path in the plasma gun and creates an electrical contact between the plasma gun and the nozzle.

8123146, Feb 28, 2012

Jan 25, 2007

11/657664

David Hawley - Kings Park NY, US
Ronald J. Molz - Mt. Kisco NY, US
James Leach - Enfield CT, US

Sulzer Metco (US) Inc. - Westbury NY

B05B 1/24
A01G 25/09

239 1, 239 79, 239 83, 239 84

Shaping the feed wire for a combustion wire thermal spray process improves the operating capability of the combustion wire gun through higher feed rates and high operating efficiencies. The efficiency of the wire melting is increased over conventional systems through increasing the surface area of the wire cross section and exposing more of the wire material directly to the burner jets.

60682019, May 30, 2000

Nov 5, 1998

9/186812

David Hawley - Kings Park NY
Dale R. Moody - Centerport NY

Sulzer Metco (US) Inc. - Westbury NY

A01G 2700

239 69

A figure eight mechanism moves a thermal spray gun over a substrate such that the deposit pattern has a figure eight configuration. The mechanism and thereby the thermal spray gun and the pattern are traversed along the substrate. The mechanism is such that, when driven by an input drive of constant speed, the deposit travels along the configuration at a non-uniform velocity. A drive system provides an input drive with varying speed so as to reduce the non-uniformity of the velocity. In one aspect a motor has varying speed, and in another aspect a linkage between a constant speed motor and the mechanism provides the varying speed.

63195607, Nov 20, 2001

Mar 29, 2000

9/538074

David Hawley - Kings Park NY
Montia Nestler - Farmingdale NY
Kevin Varley - Smithtown NY

Sulzer Metco (US) Inc. - Westbury NY

C23C 412
B05B 312

427446

A method and apparatus for coating the outer surface of a workpiece comprises disposing a workpiece in a fixed position along an axis and rotating a thermal spray gun around the axis on a support with a thermal spray thereof directed towards the axis. The powder, fuel and oxygen are rotatably coupling to the gun and the thermal spray gun and the support are moving along the axis while rotating.