Innovation Plasma Nozzle Techniques For Elimination Overspray

A Small Business Innovation Research (SBIR) endeavor by Plasma Processes, Inc., has led to the development of bell-contoured plasma nozzles that produce better coatings and higher process efficiencies. These vacuum plasma spray (VPS) nozzle configurations reduce overspray as they optimize material deposition quality of vacuum and air plasma spray coatings and structures. Overspray reductions of copper and copper alloys are cut in half, while reductions in tungsten overspray produce denser, less porous coatings than previously possible.

Possible utilizations of the technology are numerous. The advances have already been used to successfully spray-form tungsten crystal growth furnace (CFG) cartridge tubes for processing materials in microgravity. Also, bell-contoured VPS nozzles have been designed for the Department of Energy to spray gradient materials for nuclear fusion reactor components. The research also promises numerous viable opportunities in the biomedical field. Aerospace applications include coating or forming of rocket and jet engine combustors, blades, vanes, seals, and bearings.

Following the successful completion of these efforts, MSFC awarded Plasma Process six Phase III contracts.