Thermal spray coating also has been implemented by intermittent detonations, e.g., by the use of a detonation gun (D-Gun). D-guns can be used for coating a wide variety of materials, such as metals, cermets, and ceramics. D-guns typically havea relatively long (often about 1 m), fluid-cooled barrel having an inner diameter of about one inch. Typically, a mixture of reactive gases, such as oxidizer and acetylene, is fed into the gun along with a comminuted coating material in two phases. Thereactive gas mixture is ignited to produce a detonation wave, which travels down the barrel of the gun. The detonation wave heats and accelerates the coating material particles, which are propelled out of the gun onto a substrate to be coated.
The detonation wave typically propagates with a speed of about 2.5 km/sec in the tube and can accelerate the particle-laden detonation products to a velocity of about 2 km/sec. However, coating particles never reach the velocity of detonationproducts due to inertia. In practice, particle velocities usually are lower than about 900 m/sec. The temperature of the detonation products often reaches about 4000 K. After the coating material exits the barrel of the D-gun, a pulse of nitrogentypically is used to purge the barrel. Newer designs of the D-guns allow operation frequencies of up to about 100 Hz. See, e.g., I. Fagoaga et al., "High Frequency Pulsed Detonation (HFPD): Processing Parameters" (1997).
One example of a gas detonation coating apparatus is illustrated in U.S. Pat. No. 4,669,658 to Nevgod et al. A barrel enclosed in a casing has annular grooves made on an inner surface of an initial portion thereof. A main pipe housing a sparkplug and having annular grooves on its inner surface is inserted into the initial portion of the barrel. In operation, a gas supply means is turned on. The apparatus works in cycles, each cycle accompanied by gas flowing into the barrel and the mainpipe through tubes, gas conduits, and additional pipes. After the gases fill the barrel, the gas mixture is ignited in each cycle with the aid of the spark plug. The detonation products are said to quickly heat up the walls of the barrel and theannular grooves.
According to Nevgod, the gases flowing into the barrel are heated up in two stages. During the first stage the gases are warmed up in the additional pipes heated up in cycles by the detonation products. The heat insulation tubes are said toprevent the pipes from cooling down. During the second stage, the gases are heated up in the barrel and partially in the main pipe. The annular grooves on the inner cylindrical surface of the initial portion of the barrel, the inner surface of the mainpipe and on the inner surface of the cover on the end of the barrel, are said to enhance the efficiency of heat exchange with the gases due to an increase in the heat exchange area and due to gas turbulization. The gases are heated to a temperatureapproximating that of self-ignition. A plurality of ignition sites is provided to accelerate the burning process.
Presently available detonation coating devices suffer from several drawbacks. One major drawback is that the devices are implemented at a scale that makes coating of internal surfaces and difficult-to-reach spaces difficult, if not impossible. For example, present D-guns are unsuitable for coating the internal surface of tubes having an internal diameter smaller than about 10 cm. One HVOF system recently was modified to enable coating inside of a cylinder borehole of an engine block. Thiswas done to permit coating of metallic materials over ceramic surfaces of the cylinder bores. However, because of the size limitations inherent to HVOF systems (e.g., the need for a cooling jacket, the relatively large nozzle diameter, the large sizecombustion chamber and the bulky gas feed lines), this technology is unsuitable for coating the inside surfaces of long, small-diameter tubes. In addition, large particles used in HVOF systems need substantial distances to achieve the velocities andtemperatures needed for producing coatings having an acceptable quality.
There remains a need for technology for coating difficult-to-reach surfaces, particularly for applying coatings that provide protection against corrosion, erosion, and wear. It would be desirable to develop thermal spray coating technology thatenables the use of a miniaturized coating apparatus, especially one that can be adapted for coating difficult-to-reach surfaces, especially the inside surfaces of small-diameter tubes, the inner surfaces of cylinders, the inner surfaces ofconverging/diverging shapes, the inner surfaces of small rectangular tubes, the inner surfaces of shapes that are partially open, and the inner surfaces of various other non-cylindrical shapes.
SUMMARY OF THE INVENTION
The present invention is directed to a method and apparatus for producing a coating on a substrate using a pulsed detonation gun. According to one embodiment, a pulsed detonation gun comprises a small-diameter detonation tube, an igniter, and anoutlet for discharging detonation products. A detonable mixture containing a coating precursor is formed in the detonation tube, and the detonable mixture is ignited to produce detonation products containing the coating precursor. The coating precursoris discharged through the nozzle and is contacted with the substrate to produce a coating.
In another embodiment, a coating material is produced in situ by reaction of a coating precursor in a detonable or reactive mixture. The coating precursor is intermittently injected into the detonation tube together with other component(s)(e.g., fuel and oxidizer) to form a detonable or reactive mixture. The detonable or reactive mixture is ignited to produce high-temperature detonation or reaction products, e.g., during a detonation process or a deflagration process. The detonation orreaction products heat and accelerate the coating material through the detonation tube and toward the surface to be coated.
The pulsed detonation gun of the present invention is particularly useful for directly depositing coating material(s) over internal surfaces of tubes and other hard-to-reach surfaces of a substrate, such as the inner surfaces of cylinders, theinner surfaces of converging/diverging shapes, the inner surfaces of rectangular tubes, the inner surfaces of shapes that are partially open, and the inner surfaces of various other non-cylindrical shapes.
The material(s) are deposited by high velocity gas products produced in intermittent detonations or an intermittent injection and deflagration process. The detonation tube and its associated fuel/oxidizer supply lines can be constructed at asufficiently small scale that allows their insertion into long, small-diameter tubes, and permits their use in coating various other difficult-to-reach surfaces. Of course, the apparatus of the present invention also is useful for coating a wide varietyof large-diameter tubes, such as gun barrels, tubes used in oil industries, tubes used in food industries, etc.
The detonation products produced by the pulsed detonation gun accelerate and heat the coating precursor or coating material particles to high kinetic energies, resulting in high quality coating depositions that can provide such properties ascorrosion-, erosion-, and wear resistance. Existing thermal spray coating equipment is unsuitable for applying such coatings to the inner surfaces of small-diameter tubes and many other difficult-to-reach surfaces.
The pulsed detonation coating device of the present invention avoids the need for forced water- or air-cooling because the internal volume of the device is exposed to the relatively cold injected gases between the occurrences of detonations,which are characterized by very short periods of high pressure and temperature conditions. The device can be operated with a relatively low gas line pressure and does not require a separate combustion chamber. These factors each contribute to theability of constructing the device at scale substantially smaller than is possible with presently available technologies.
According to another embodiment of the present invention, a method for producing a coating on a substrate comprises providing a pulsed detonation gun comprising a detonation chamber, an igniter, and an outlet for discharging detonation products. A coating precursor is mixed with fuel or oxidizer, such as by forming a suspension of coating precursor particles in fuel or oxidizer, prior to injection into the detonation chamber. The detonable mixture is ignited to produce detonation productscontaining the coating precursor. The coating precursor is contacted with the substrate to produce a coating on the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in more detail with reference to preferred embodiments of the invention, given only by way of example, and illustrated in the accompanying drawings in which:
FIG. 1A is a three-dimensional model of the cross section of a pulsed detonation coating apparatus, shown inside a small-diameter tube, in accordance with a preferred embodiment of the present invention;
FIG. 1B is a schematic illustration of the cross section of the pulsed detonation coating apparatus shown in FIG. 1A;
FIG. 2 is a schematic illustration of a pulsed detonation coating apparatus operated in a low pressure or vacuum chamber in accordance with an alternative embodiment of the present invention; and
FIGS. 3A-3E illustrate several variations for the detonation tube outlet; FIGS. 3A and 3B show alternate showerhead configurations; FIGS. 3C and 3D illustrate nozzles that are displaceable to a plurality of coating positions.
DETAILEDDESCRIPTION OF THE INVENTION
The pulsed detonation coating apparatus of the present invention has utility in applying a wide variety of coating materials to a wide variety of substrates and is particularly useful in coating the inside surfaces of small-diameter tubes andother difficult-to-reach surfaces, such as the inner surfaces of cylinders, the inner surfaces of converging/diverging shapes, the inner surfaces of small rectangular tubes, the inner surfaces of shapes that are partially open, and the inner surfaces ofvarious other non-cylindrical shapes, to improve such properties as corrosion-, erosion-, and wear resistance. Nanoscale ceramic particles can be used, for example, for coating lightweight, low melting point metals used in aircraft structures to imparterosion- and corrosion resistance. Coatings of polytetrafluoroethylene, polymers, and other plastic materials can be applied to the inside surfaces tubes, for example, for corrosion protection and to improve lubricity and other tribological propertiesof the inner surfaces of the tubes. Metal and metal composite materials, such us Al/SiC, can be coated on the inner surfaces of cylinders of internal combustion engines. As another example, corrosion/erosion protective materials such asalumina/titania, Cr, WC/Co, Ni and Cr based alloys, and other similar materials can be applied to tubes/pipes used in geothermal energy exploration, which often are subjected to high-temperature corrosive environments. Similar coatings may be applied totubes/pipes that are used to transport corrosive/erosive liquid, gases, and suspensions used in oil exploration, chemicals industry, and energy generation and energy delivery industries. Thermal barrier coatings based on zirconia, alumina, and similarmaterials can be applied to metal tubes for protection from very high temperature gas or liquid flow and for reduction of thermal losses.
The term "detonation," "detonation process," and similar terms are used herein refer to a physical phenomena characterized by a shock wave propagating in front of a reaction front. The shock wave compresses the initial mixture to high pressuresand high temperatures so as to initiate a very high initial rate of reaction behind its front. The detonation front propagates with supersonic speeds, typically on the order of about 1000 to 3000 m/sec.
The term "deflagration process," as used herein, refers to a combustion process in which a reaction front propagates slowly through the mixture via diffusion and thermal initiation. Combustion of the unconfined mixture does not yield the highpressures that are characteristic of detonation. The combustion front propagates with subsonic speeds, typically on the order of about 1 to 30 m/sec.
The term "detonable mixture," as used herein, refers to the components present in the detonation tube at the time of detonation. One example of a detonable mixture is oxygen, a fuel detonable in mixtures with oxygen, and a coating precursor. Another example of a detonable mixture is a monopropellant, such as nitromethane or nitrobenzene, and a coating precursor. As another example, a detonable mixture can comprise a detonable coating precursor and an oxidizer. The term "reactive mixture"refers to the components present m the detonation tube at the time of a deflagration process.
The term "coating precursor," as used herein, refers to (1) material that can be heated and accelerated in a detonation process to form a coating, or (2) material that can react during a detonation process or a deflagration process to form acoating material in situ. The coating precursor can comprise, by way of example, particles such as metals, cements, ceramics, polymers, or combinations thereof. The term "detonable coating precursor," as used herein, refers to materials which functionas both a coating precursor and as a fuel. Non-limiting examples of detonable coating precursors include gaseous and liquid metalorganic compounds, such as silane, disilane, germane, tungsten hexaflurade, trimethylboron, cadmium acetate, magnesiumethoxide, tantalum V-methoxide, tungsten V-ethoxide, zinc naphenate, and zirconium
The coating precursor may be in a variety of physical forms. For example, the coating precursor may comprise metal particles, which can be pre-mixed with the fuel or oxidizer before injection into the detonation tube. During the detonationprocess, the coating precursor particles are heated and are liquefied or semi-liquefied. The resulting detonation products act as a carrier for the liquefied or semi-liquefied coating precursor, which forms a coating on the substrate. The coatingprecursor alternatively can be in the gaseous phase, and may form coatings, for example, upon interaction with the substrate via chemical reaction, physical sintering, or both.
Examples of fuels that can be used include, but are not limited to, those detonable in mixtures with oxidizer such as hydrogen, methane, propane, acetylene, or propylene. Also, detonable mixtures of liquid fuels and oxidizer can be used, e.g.,kerosene/oxygen, alcohol/oxygen, benzene/oxygen and other similar mixtures. In addition, some detonable monopropellants can be used, such as nitromethane, nitroglycerin, or similar single-component fuels that can be detonated. Selection of a suitablefuel will be apparent to persons skilled in the art and forms no part of the present invention.
Non-limiting examples of oxidizers include oxygen, air, mixtures of oxygen and nitrogen, mixtures of oxygen and one or more inert gases such as helium and argon. The relative amounts of nitrogen or inert gases vary over a wide range and can besuitably selected by persons skilled in the art with the aid of no more than routine experimentation.
For solid coating precursors, the size of the particles can vary over a wide range. Often the mean particle size is about 50.mu. or less. Smaller micron particle sizes also can be used, such as those having a mean particle size of less thanabout 20.mu. or 10.mu.. In one embodiment of the invention, sub-micron sized particles can be used, having a mean particle size of less than 1.mu., and can have a mean particle size as small as about 100 nm, 10 nm, or less. The coating precursortypically is supplied in an inert liquid or gaseous carrier, such as water, nitrogen, argon, or helium.
A preferred embodiment of the present invention is illustrated in FIGS. 1A and 1B. FIG. 1A is a three-dimensional model illustrating a pulsed detonation coating apparatus (1) inside of a small-diameter tube (25), e.g., having a diameter of about2 cm. FIG. 1B illustrates a cross-sectional view of the apparatus of FIG. 1A, including a blown-up view of a portion of the coating apparatus (1) inside the small-diameter tube (25). The apparatus (1) includes a small-diameter detonation tube (22) forreceiving a detonable mixture containing a coating precursor, and a detonation tube outlet (30) for discharging detonation products. The detonation tube (22) preferably has a sufficiently small diameter to enable the apparatus (1) to easily fit intosmall-diameter tubes, e.g., tubes having a diameter of about 10 cm, 5 cm, 2 cm or even less. The detonation tube (22) most often has a diameter of about 20 mm or less, more usually about 5 mm or less. In one preferred embodiment, the detonation tube(22) has a diameter of less than about 2 mm. The detonation tube is described herein with reference to cylindrical shapes. However, it should be understood that the geometry of the detonation tube is not limited to cylindrical shapes; for example, thedetonation tube may have a rectangular cross-section. In the context of non-cylindrical tubes, the term "diameter" refers to the diameter of a circle having the same area as the cross-sectional area of the non-cylindrical tube, or in the case of tubeshaving non-uniform cross-sections, the maximum cross-sectional area of the tube.
A first injector (14) feeds oxidizer into the detonation tube (22). A second injector (16) feeds fuel into the detonation tube (22). The oxidizer (14) and fuel (16) injectors each have miniature valves for controlling the flow of oxidizer andfuel, respectively. The coating precursor typically is co-injected together with fuel and oxidizer into detonation tube (22) to form a detonable mixture. In a preferred embodiment, the coating precursor is pre-mixed with the oxidizer or fuel prior toinjection. In some cases it may be possible to co-inject the coating precursor into the detonation tube (22) via a separate inlet (not illustrated). Normally, the components of the detonable mixture (e.g., oxidizer, fuel, and coating precursor) aresimultaneously co-injected at predetermined intervals. It is also possible to co-inject the components of the detonable mixture sequentially, if desired.
A suspension of the coating precursor and fuel can be formed and injected into the detonation tube (22). The suspension can be mixed with an oxidizer in the detonation tube (22) to form a detonable mixture. If the fuel is a monopropellant, thesuspension can be injected, dispersed, and ignited, e.g., the suspension itself can form the detonable mixture. This embodiment is particularly advantageous for the direct processing of nanoscale particles into coatings. The suspension provides foreasy injection and uniform dispersion of the coating particles and avoids such problems as clogging of the particle injection line, e.g., resulting from particle agglomeration. Smaller particles also tend to be more reactive and thus difficult tohandle. For example, sub-micron particles of Cu and Ti can self-ignite in air. Mixing the particles with fuel isolates the particles from atmospheric oxygen, reducing handling hazards.
Optionally, two or more coating precursors can be alternatively injected into the detonation tube (22). The changing from one coating precursor to another coating precursor can be done at predetermined intervals (e.g., alternating eachdetonation, every other detonation, every fifth detonation, etc.) or can be actuated manually by an operator. Multiple coating precursors may be used, for example, to create a complex multi-layered coating material on a substrate using a single coatingapparatus.
The detonable mixture is ignited by suitable igniter, such as a spark plug, laser, pyrotechnic device, or the like. FIG. 1B illustrates spark plug electrodes (18) located on the inner wall of the detonation tube (22). Each detonation creates adetonation wave that propagates through the detonation tube (22). The resulting high-temperature and high-pressure detonation products heat the coating precursor particles and accelerate the particles through the detonation tube (22). The coatingprecursor particles are discharged through the detonation tube outlet (30) and toward the inside surface of the small-diameter tube (25) or other substrate to be coated. The frequency of detonations can vary over a wide range and can be suitablyselected to meet the needs of a particular application, as will be apparent to persons skilled in the art. The operating frequency most often ranges from about 0.1 to 1,000 Hz.
The intermittent operation of the pulsed detonation coating apparatus (1) avoids the need for separate cooling equipment because intermittent injection of the relatively cold gases between the brief periods of high-temperature detonation enablesrelatively low temperatures to be maintained in the detonation tube walls (22). Nevertheless, to prevent damage to valves and other system elements, in some cases it may be advantageous to blow air or inert gas through the inner volume of the detonationtube over the valves and other elements of pulsed detonation coating apparatus (1), or to provide cooling in some other fashion.
In an alternative embodiment of the present invention, a coating material is synthesized in situ during an intermittent detonation or deflagration process. A coating precursor is pre-mixed with oxidizer or fuel, and the components areco-injected into the detonation tube (22) to form a detonable or reactive mixture. A detonable coating precursor also may be used, can be co-injected with an oxidizer as in the previous embodiment. When the detonable or reactive mixture is ignited, thecoating precursor reacts in the high-temperature detonation or reaction products to yield coating materials that are accelerated through the detonation tube (22), through the detonation tube outlet (30), and toward the inner surface of the small-diametertube (25) or other surface to be coated.
As illustrated in FIG. 2, the coating process can be implemented in a vacuum or reduced pressure environment. The lower pressures are particularly useful for coating with small particles and nanosized particles. For example, the small-diametertube (25) or other substrate to be coated can be situated in a low-pressure or vacuum chamber (40). The valves, controls, etc. preferably are disposed outside of the vacuum chamber (40) for easy operator access, while the fuel, oxidizer, inertgas/precursor materials, and ignition lines are fed through the wall of the low-pressure or vacuum chamber (40) without interfering with the vacuum or low-pressure environment. Any suitable low-pressure or vacuum means can be used for maintaininglow-pressure or vacuum within the low-pressure chamber. The term "low pressure" refers to pressures lower than atmospheric (less than 1 atmosphere) and typically on the order of 10.sup.-1 of atmospheres and lower, often on the order of 10.sup.-2 to10.sup.-3 atmospheres and lower. The term "vacuum" refers to pressures of 10.sup.-6 atmospheres and lower.
The low pressure environment provides a greater pressure gradient in relation to the detonation pressure, which imparts increased kinetic energy and impact energy to the coating particles, resulting in high quality coatings. The detonationproducts expand from the high-pressure, high-temperature environment of the detonation tube (22) to the low-pressure environment of the low-pressure or vacuum chamber (40). By maintaining low pressure near the substrate (25), it is possible to producehigh quality coatings using small-micron scale and even nanoscale-sized particles. The particles are effectively accelerated in the expanding detonation products and do not appreciably decelerate at the substrate because of the very small drag force inthe low-density and low-pressure environment. In general, the drag force is smaller for smaller particles. In the low-pressure environment, the characteristic size of smaller (e.g., nanoscale) particles approaches that of the collision free path formolecules of the low-pressure carrying gas. Thus, small-micron size particles generally require lower pressures than do smaller, nanoscale particles for the same drag force at the substrate environment.
In the low-pressure or vacuum chamber (40), the coating precursor particles are accelerated to high velocities. The particle velocities can vary over a wide range depending on such factors as particle size, detonation pressure, detonationtemperature, and the pressure in the low-pressure chamber. Typical particle velocities are in excess of about 2 km/sec., often 3 km/sec., 4 km/sec., 5 km/sec., or even higher. Because the high temperature detonation products heat the coating precursorparticles, the coating particles generally are in a liquefied or semi-liquefied state.
The low-pressure environment also effectively removes or reduces the amount of carrier gases from the detonation products as the detonation products are accelerated toward the substrate (25), resulting in relatively low pressure at the substratesurface. This is especially significant for coatings using small-micron and nanosized particles, which are particularly susceptible to being decelerated and diverted away from the substrate by turbulent gas flow in the vicinity of the substrate surface. Such a problem is encountered, for example, in conventional HVOF coating
A spark plug (18) or other suitable igniter is provided to ignite the fuel in the detonation tube (22), producing detonation products containing the coating precursor. The detonation reaction produces a brief period of extremely high temperatureand high pressure inside the detonation tube (22). Typical detonation temperatures are on the order of 4000 K, and pressures on the order of 20-30 atmospheres and higher. The period of each detonation most often is less than about 10.sup.-3 sec. andcan be as small as about 10.sup.-4 sec., 10.sup.-5 sec., or even less. Shorter periods of detonation can reduce or avoid appreciable local heating of the substrate, and also can permit operation at high frequencies, e.g., as high as 1000 Hz or higher. Shorter periods of detonation also can help avoid or reduce particle grain growth, particularly with nanosized particles.
The detonation tube outlet (30) preferably includes configured openings and/or a nozzle for directing the detonation products toward the substrate (25) to produce a coating. A wide variety of configurations are possible and may be particularlyadapted for coating the inside surfaces of the small-diameter tubes (25) and various other difficult-to-reach portions of substrates, such as the inner surfaces of cylinders, the inner surfaces of converging/diverging shapes, the inner surfaces of smallrectangular tubes, the inner surfaces of shapes that are partially open, and the inner surfaces of various other non-cylindrical shapes. Several examples of showerhead and nozzle configurations are illustrated in FIGS. 3A-3E. Other configurations maybe suitably selected for coating particular substrates and should be considered to fall within the scope of the present invention.
The detonation tube outlet (30) may include a plurality of openings, such as in a "showerhead" type configuration, as illustrated in FIGS. 3A and 3B. FIG. 3A illustrates a plurality of openings (30A) located along one side of the detonation tube(22). The apparatus, when placed inside the center of a tube, can coat the inner surfaces of the tube (25) that is opposite to the openings (30A), as illustrated in FIG. 3A. Alternatively, as illustrated in FIG. 3B, a number of openings (30B) may beprovided at positions along the circumference of the detonation tube (22) to simultaneously coat the entire adjacent inner circumference of the tube (25).
As illustrated in FIGS. 3C and 3D, the detonation tube outlet (30) may include a flexible nozzle (30C, 30D) that can be bent and displaced to a plurality of coating positions, as shown in the solid and phantom lines in FIGS. 3C and 3D. The smalldiameter of the detonation tube (22) enables a suitable flexible nozzle (30C, 30D) to be more easily constructed than would be the case for a larger diameter nozzle. Alternatively, a fixed nozzle may be employed. The fixed nozzle can be oriented at apredetermined angle best suited for coating a particular substrate surface. Any suitable angle may be selected for the nozzle orientation, e.g., 0 to 45.degree., 45 to 90.degree., or 90 to 135.degree. relative to the axis of the detonation tube (22).
FIG. 3E illustrates an alternative embodiment in which a device includes a plurality of pulsed detonation guns (1), each of which has a structure as previously described. FIG. 3E illustrates three detonation guns, each having a detonation tube(22) and a nozzle (30E) oriented at different predetermined angle. While three guns are illustrated in FIG. 3E, it is contemplated that a multi-gun device may include two, four, or possibly even more guns. Because the coating can be simultaneouslyapplied at different angles by virtue of the plural guns, fixed-angle nozzles are preferred in this embodiment. However, it also is contemplated that flexible nozzles may be used.
The pulsed detonation coating apparatus (1) of the present invention can be constructed substantially smaller than conventional D-guns, permitting its use for coating the inside surface of small-diameter tubes (25) and various otherdifficult-to-reach substrate surfaces. The total length of the pulsed detonation coating apparatus (1) preferably is about 50 cm or less. It is contemplated that coating guns (1) of the present invention can have a total length of about 5 cm or evenless.
The intermittent detonations advantageously enable the surface of the substrate (25) to cool between coated layers. This enables high deposition rates of coating materials, such as metals or ceramics, onto a wide variety of substrates,especially those, such as plastic, that have low melting point surfaces. If necessary, the surface of the substrate (25) can be subjected to rapid temperature quenching, for example after each detonation exposure or at other suitable intervals. Thiscan be done, for example, by intermittently spraying nitrogen onto the substrate surface between exposures. Quenching can be also achieved by injecting liquids such as water, ethyl alcohol, or inert gases such as helium or argon between the cycles intothe detonation tube (22).
At particle velocities in excess of 2 km/sec., some particles will fuse into coatings, even at low temperatures, and create a strong bond with the substrate surface. Excessive heating of the substrate surface can result in previously coatedlayers being damaged. By avoiding overheating of the substrate surface, the intermittent detonation process of the present invention permits high quality coatings to be applied at high coating rates.
While particular embodiments of the present invention have been described and illustrated, it should be understood that the invention is not limited thereto since modifications may be made by persons skilled in the art. The present applicationcontemplates any and all modifications that fall within the spirit and scope of the underlying invention disclosed and claimed herein.