CA2142543A1 - Coated substrate and method of coating same - Google Patents
Coated substrate and method of coating sameInfo
- Publication number
- CA2142543A1 CA2142543A1 CA 2142543 CA2142543A CA2142543A1 CA 2142543 A1 CA2142543 A1 CA 2142543A1 CA 2142543 CA2142543 CA 2142543 CA 2142543 A CA2142543 A CA 2142543A CA 2142543 A1 CA2142543 A1 CA 2142543A1
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- Prior art keywords
- substrate
- coating
- wire
- weldments
- welding
- Prior art date
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Abstract
A method of coating a substrate capable of being welded which includes welding segments of wire onto the substrate to form a plurality of upstanding segments and coating the substrate with a coating material.
Description
- ~142543 COATED SUBSTRATE AND METHOD OF COATING SAME
FIELD
The present invention relates to a method of coating a weldable substrate with a desired material so as to form a very strong mechanical bond between the coating and the substrate.
1 0 BA~;K~UND
In general, one can often enhance the performance of a substrate by applying a coating of another material having the desired performance characteristics. For example, such coatings may alter in a desired manner the surface friction of the substrate, act as a sealant or improve the wear characteristics.
Many industrial services or processes that experience rapid, inconvenient or expensive wear degradation of equipment could derive benefit from the use of these highly durable coating materials. Most such coatings depend on development of a chemical bond between the substrate and the coating. However, such bonding is hampered by the difficulty in bonding the coating to soiled or contaminated surfaces as well as the tendency of the bonds to weaken due to impact, vibration, and different thermal expansion coefficients of the substrate and coating. Moreover, in order to create a proper chemical bond between the coating and the substrate it is necessary to properly prepare the bonding surface of the substrate.
Usually one must sand blast or etch the substrate first in order to clean it properly. Such treatment does not increase significantly the bond interface area and leads to problems with the residue of sand or acid. Many industrial components cannot be 21~2543 -positioned for sandblasting or the resulting residue collected or contained.
Contaminants such as oils, acids, salts, moisture and surface corrosion frequently work to reduce the available adhesion of a bond and must therefore be either greatly reduced or eliminated altogether. These contaminants often penetrate some distance beneath the surface of the substrate where normal surface preparation techniques fail to fully eradicate them. In addition, inconsistent expertise or diligence on the part of the applicator leads to a lack of consistency and predictability in the reliability of the bond.
Assuming a reasonably satisfactory bond is formed between a coating and a substrate, the forces and elements that work to weaken this bond are relentless. A
typical application consists of bonding a rigid metal substrate and a high-strength compound. These materials remain in contact or bonded to one another only through a very narrow interface zone. All of the forces caused by differing thermal expansion properties, impact shock and vibration are therefore very highly concentrated in the narrow bond interface region. Once there is partial or complete loss of adhesion, typically there follows displacement of the coating material through flaking, scaling or cracking. Once the latter flaws occur, undercutting and hydraulic and other forces frequently result in wide-scale damage to the additive coating. In addition, the damage caused by impact shock may travel a considerable distance through the interface.
In order to create less dependence on the chemical bond, different techniques have been developed to add strength through an additional mechanical bond.
One technique is to spot weld expanded metal at dispersed locations over the substrate and then apply the coating \patents\cap\spec\stel23ap.doc -in its uncured state. Once cured, the expanded metal assists in holding the coating material together. Even if separation between the coating and the substrate occurs, the expanded metal helps retain the coating material in place longer than would be the case without the expanded metal. Typically, the coating has an abrupt leading edge profile. Thus, a "ramp" of additive material leading up to the expanded metal from the substrate cannot enjoy the benefit offered by the expanded metal. As a result, undercutting wear at the leading edge of the coating material often takes place.
When the coating over the expanded metal wears and exposes the expanded metal, the latter wears rapidly as it is generally softer than the coating. Such wear leads to voids or pockets and thereafter new multiple leading edges. Such action accelerates the effective wear and tear and frequently leads to premature failure of the coating bond to the substrate.
Another drawback to the use of expanded metal overlay lies in its resistance to conforming closely to the shape and contours of the substrate. Irregular shapes, complicated patterns, compound curves, surface contours such as those found in reducer pipes, elbows, pumps and other castings or shapes as found in screw conveyers, paddles and paddle fans, shrouds, augers, venturi tubes, etc. illustrate the difficulty of forming expanded metal to closely follow the surface to be coated.
The most commonly utilized method of on-site repair or rebuilding of a wear surface such as those originating with concrete pumps, elbows and piping, augers, fans, chipper disc pockets and shrouds, etc. is the welding in place, onto the worn substrate of stringer beads of hard facing deposits. These welded beads \patents\cap\spec\stel23ap.doc _ typically are located fairly close together in parallel rows and may be built up one on another. They commonly appear as rounded mounds with valleys or low points between the mounds. The advantage of this method is that it requires low skill and yet provides predictable service life and reasonable cost. Minor substrate contamination and less than ideal environmental conditions do not present much of a problem and normally will not interfere with successful applications. Hard-face welding has been in practice for many years and iswell understood. On the other hand, wear rates and patterns can be somewhat irregular, perhaps due to the varying thickness of the deposits or perhaps the rolling peaks and valleys. Attempting to build up multiple or thicker layers in order to extend service life is very costly in terms of both time and material. Multiple-layered buildups over severely thinned base material is tricky and frequently results in unacceptable warpage and cracking, or burn-through of the substrate. The arc welding of stringer beads also tends to create a concentration of stress lines at or near the junction of the substrate and the bead itself. Overhead and vertical applications are very difficult and thin substrates that lack in structural integrity may not stand up to this very intrusive rebuilding or "hard-facing" methodology.
U.S. Patent No. 3,877,961 issued to Tank et al.
discloses a method of increasing the adhesive strength of a ceramic layer to a metallic base by way of increasing the surface of the metallic base through an application of a monogranular layer of metal granules to the base.
The individual granules may have irregular outer shapes and grain sizes. In between the individual granules there are gaps so that many successive height differences are developed. The granules are non-detachably connected to the base by soldering or sintering to form an intermediate layer with a desired profile. Finally a \patents\cap\spec\stel23ap.doc 21~2543 -layer of ceramic is thermally sprayed onto the monogranular layer. The ceramic coating is accomplished by placing the monogranular layer and substrate in a vacuum furnace at a temperature of about 1,150 C and then thermally spraying on the ceramic coating such as aluminum oxide. However, often it is not practical to place the substrate in a vacuum furnace as it may be a loading ramp, the deck of a bridge or some other large immovable object. Moreover, it is often not desirable to raise the temperature of the substrate for other reasons.
In addition, where significant impact may occur it is often insufficient to have merely small irregularly shaped granules as the interfacing material between the substrate and the coating material.
Accordingly, it is an object of the invention to provide an improved method for coating a substrate.
It is a further object of the invention to provide a method of coating a substrate which can be done in the field in overhead, vertical or horizontal surfaces. It is yet a further object of the invention to provide a coating method which can coat a substrate with a variety of materials and to substrates with soiled or contaminated surfaces. Another object of the invention is to provide a method of coating a substrate which does not require raising the temperature of the substrate significantly and which can successfully create a strong bond between the substrate and the coating materials.
SUMMARY OF THE INVENTION
According to the invention there is provided a method of coating a substrate with another material which includes welding to the surface of the substrate a plurality of wire segments to form a layer of upstanding weldments and then spreading the coating material between and over the weldments.
\patents\cap\spec\stel23ap.doc . _ The weldments are oriented in three-dimensional, jagged, irregular patterns which greatly increase the total surface area and hence the chemical and mechanical bond between the coating and the substrate.
Preferably, the coating material is malleable and curable to an altered, non-malleable state. For example, the coating material may be a granular material containing a bonding agent.
The lengths of the segments may be different and one end thereof may be fused with the material of the substrate.
The shape and profile of the weld deposits can be easily varied to provide the optimum support of the particular coating material depending on the service requirements. Once the coating material is pushed into the mesh formed by the welded wire segments, the weld and coating work together to provide mutual support. The additive materials may be wear prevention materials, friction enhancing or reducing materials, impact-absorbing materials, etc., that enhance the performanceof the substrate or provide some other desired benefit.
The weld deposits aid in supporting the coating material by spreading impact into substrate material and greatly decreasing the risk of delamination. The welded wire segments function much as reinforcing rod in concrete by helping to hold the bonded material together as well as to hold it by mechanical means to the substrate. The very rough surface of the weld deposits provides a full three dimensional interlocking grip of the coating material. The weld deposit improves the bonding of the coating when applied to overhead, or \patents\cap\spec\stel23ap.doc ~142543 vertical surfaces. The weld deposits also enable bonding of the coating in the presence of substrate contamination by oil, acids, etc. Advantageously, the process may be applied to worn, damaged or paper-thin surfaces of the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, as well as other features and advantages thereof, will be best understood by reference to the description which follows read in conjunction with the accompanying drawings, wherein:
Figure 1 is a schematic diagram showing the apparatus for welding wire segments onto a substrate;
Figure 2 is a plan view showing the serpentine pattern of the initial welding pass;
Figure 3 is a cross sectional view in elevation of the substrate taken along the line 3-3 of Figure 2 after the first pass; and Figure 4 is a cross sectional view in elevation of the substrate taken along the line 3-3 of Figure 2 after the second pass of welding and after the coating has been applied.
DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS
Referring to Figure 1 there is shown the apparatus used for welding on wire segments to a substrate 28. A suitable such apparatus is a Lincoln Wirematic 250 supplied by Lincoln Electric Company. A
welding power supply 10 is connected to a wire driver 12 \patents\cap\spec\stel23ap.doc 2142~43 ~_ - 8 -that has a pair of drive rollers 18 that grip wire 16 from a spool 14 and drive it through a center of cable 20 coupled to the wire driver 12. Near the end of cable 20 there is mounted a lever 22 which activates the drive rollers 18. To the exit end of cable 20 a replaceable contact tip 24 is inserted which serves to conduct current which passes down cable 20 through a braided copper conductor 23, shown only schematically, to wire 16. The wire 16 exits from the contact tip 24. Wire end 26 which has exited from cable 20 extends down to metallic substrate 28. Metallic substrate 28 is grounded to the power supply 10 through clip 30 and ground line 32.
As wire 16 is fed through the cable 20 and past the contact tip 24, the voltage applied between the wire 16 and the substrate 28 causes a discharge at the tip of the wire which melts a segment of the wire end 26 and a local portion of the substrate resulting in the formation of a weldment which fuses with the metal of the substrate 28. As the length of end 26 is increased, the voltage of the power supply 10 must be increased slightly to compensate for the slightly longer length of wire end 26.
As the speed of the wire feed rollers 18 is increased, the voltage must also be increased in order to create a hotter arc that will melt the wire and substrate faster.
The precise combination of speed, voltage, wire size, and length of wire end 26 must be selected for the result desired.
Initially a pass is made which applies a coating of weldment in a serpentine pattern as shown in Figure 2. This layer fuses with the substrate 28 and provides an intermediate layer 34 of a desired thickness typically less than 1/2 inch as shown in cross section in Figure 3. As shown in Figure 3, the intermediate layer 34 is applied in a way that produces an irregular \paten~ts\cap\spec\stel23ap.doc ~142~4 3 topography. The method produces only limited localized heating of the substrate and therefore produces minimum warpage or intrusiveness. It can be applied to thin substrates not capable of supporting convention welding without "burn-through" or severe warpage. Moreover, the localized heating flashes off any oil or other contaminant and allows the technique to be used on a degraded or contaminated surface. The matrix of weldments can also easily be formed on a vertical or overhead surface.
Once the intermediate layer 34 is formed, a second step involves welding on segments of wire which form upstanding weldments 38 as shown in Figure 4. With the entire substrate surface covered with such weldments, the final step involves the application of a malleable uncured coating of desired material. A wide variety of coating materials are possible such as ceramics bonded with epoxy, urethanes, concrete, carbides, etc. In fact any material that is malleable in its uncured state and cures to a substantially non-malleable state may be used.
The malleable uncured coating material is worked in between the weldments and over the substrate to a desired thickness in which all of the weldments are covered.
The matrix of weldments can be easily formed on a vertical or overhead surface. The length of wire end 26 measured from its tip to the end of the contact tip 24 may be from 1/2 to 8 inches in length.
After curing, the coating 40 forms a strong interlocking mechanical bond with the substrate 28. The resultant composite structure is shown in Figure 4.
Obviously, the need to weld wire to the substrate 28 limits the substrate material to a weldable metal.
\patents\cap\spec\stel23ap.doc ~142543 Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modification or embodiments as fall within the true scope of the invention.
\patents\cap\spec\stel23ap.doc
FIELD
The present invention relates to a method of coating a weldable substrate with a desired material so as to form a very strong mechanical bond between the coating and the substrate.
1 0 BA~;K~UND
In general, one can often enhance the performance of a substrate by applying a coating of another material having the desired performance characteristics. For example, such coatings may alter in a desired manner the surface friction of the substrate, act as a sealant or improve the wear characteristics.
Many industrial services or processes that experience rapid, inconvenient or expensive wear degradation of equipment could derive benefit from the use of these highly durable coating materials. Most such coatings depend on development of a chemical bond between the substrate and the coating. However, such bonding is hampered by the difficulty in bonding the coating to soiled or contaminated surfaces as well as the tendency of the bonds to weaken due to impact, vibration, and different thermal expansion coefficients of the substrate and coating. Moreover, in order to create a proper chemical bond between the coating and the substrate it is necessary to properly prepare the bonding surface of the substrate.
Usually one must sand blast or etch the substrate first in order to clean it properly. Such treatment does not increase significantly the bond interface area and leads to problems with the residue of sand or acid. Many industrial components cannot be 21~2543 -positioned for sandblasting or the resulting residue collected or contained.
Contaminants such as oils, acids, salts, moisture and surface corrosion frequently work to reduce the available adhesion of a bond and must therefore be either greatly reduced or eliminated altogether. These contaminants often penetrate some distance beneath the surface of the substrate where normal surface preparation techniques fail to fully eradicate them. In addition, inconsistent expertise or diligence on the part of the applicator leads to a lack of consistency and predictability in the reliability of the bond.
Assuming a reasonably satisfactory bond is formed between a coating and a substrate, the forces and elements that work to weaken this bond are relentless. A
typical application consists of bonding a rigid metal substrate and a high-strength compound. These materials remain in contact or bonded to one another only through a very narrow interface zone. All of the forces caused by differing thermal expansion properties, impact shock and vibration are therefore very highly concentrated in the narrow bond interface region. Once there is partial or complete loss of adhesion, typically there follows displacement of the coating material through flaking, scaling or cracking. Once the latter flaws occur, undercutting and hydraulic and other forces frequently result in wide-scale damage to the additive coating. In addition, the damage caused by impact shock may travel a considerable distance through the interface.
In order to create less dependence on the chemical bond, different techniques have been developed to add strength through an additional mechanical bond.
One technique is to spot weld expanded metal at dispersed locations over the substrate and then apply the coating \patents\cap\spec\stel23ap.doc -in its uncured state. Once cured, the expanded metal assists in holding the coating material together. Even if separation between the coating and the substrate occurs, the expanded metal helps retain the coating material in place longer than would be the case without the expanded metal. Typically, the coating has an abrupt leading edge profile. Thus, a "ramp" of additive material leading up to the expanded metal from the substrate cannot enjoy the benefit offered by the expanded metal. As a result, undercutting wear at the leading edge of the coating material often takes place.
When the coating over the expanded metal wears and exposes the expanded metal, the latter wears rapidly as it is generally softer than the coating. Such wear leads to voids or pockets and thereafter new multiple leading edges. Such action accelerates the effective wear and tear and frequently leads to premature failure of the coating bond to the substrate.
Another drawback to the use of expanded metal overlay lies in its resistance to conforming closely to the shape and contours of the substrate. Irregular shapes, complicated patterns, compound curves, surface contours such as those found in reducer pipes, elbows, pumps and other castings or shapes as found in screw conveyers, paddles and paddle fans, shrouds, augers, venturi tubes, etc. illustrate the difficulty of forming expanded metal to closely follow the surface to be coated.
The most commonly utilized method of on-site repair or rebuilding of a wear surface such as those originating with concrete pumps, elbows and piping, augers, fans, chipper disc pockets and shrouds, etc. is the welding in place, onto the worn substrate of stringer beads of hard facing deposits. These welded beads \patents\cap\spec\stel23ap.doc _ typically are located fairly close together in parallel rows and may be built up one on another. They commonly appear as rounded mounds with valleys or low points between the mounds. The advantage of this method is that it requires low skill and yet provides predictable service life and reasonable cost. Minor substrate contamination and less than ideal environmental conditions do not present much of a problem and normally will not interfere with successful applications. Hard-face welding has been in practice for many years and iswell understood. On the other hand, wear rates and patterns can be somewhat irregular, perhaps due to the varying thickness of the deposits or perhaps the rolling peaks and valleys. Attempting to build up multiple or thicker layers in order to extend service life is very costly in terms of both time and material. Multiple-layered buildups over severely thinned base material is tricky and frequently results in unacceptable warpage and cracking, or burn-through of the substrate. The arc welding of stringer beads also tends to create a concentration of stress lines at or near the junction of the substrate and the bead itself. Overhead and vertical applications are very difficult and thin substrates that lack in structural integrity may not stand up to this very intrusive rebuilding or "hard-facing" methodology.
U.S. Patent No. 3,877,961 issued to Tank et al.
discloses a method of increasing the adhesive strength of a ceramic layer to a metallic base by way of increasing the surface of the metallic base through an application of a monogranular layer of metal granules to the base.
The individual granules may have irregular outer shapes and grain sizes. In between the individual granules there are gaps so that many successive height differences are developed. The granules are non-detachably connected to the base by soldering or sintering to form an intermediate layer with a desired profile. Finally a \patents\cap\spec\stel23ap.doc 21~2543 -layer of ceramic is thermally sprayed onto the monogranular layer. The ceramic coating is accomplished by placing the monogranular layer and substrate in a vacuum furnace at a temperature of about 1,150 C and then thermally spraying on the ceramic coating such as aluminum oxide. However, often it is not practical to place the substrate in a vacuum furnace as it may be a loading ramp, the deck of a bridge or some other large immovable object. Moreover, it is often not desirable to raise the temperature of the substrate for other reasons.
In addition, where significant impact may occur it is often insufficient to have merely small irregularly shaped granules as the interfacing material between the substrate and the coating material.
Accordingly, it is an object of the invention to provide an improved method for coating a substrate.
It is a further object of the invention to provide a method of coating a substrate which can be done in the field in overhead, vertical or horizontal surfaces. It is yet a further object of the invention to provide a coating method which can coat a substrate with a variety of materials and to substrates with soiled or contaminated surfaces. Another object of the invention is to provide a method of coating a substrate which does not require raising the temperature of the substrate significantly and which can successfully create a strong bond between the substrate and the coating materials.
SUMMARY OF THE INVENTION
According to the invention there is provided a method of coating a substrate with another material which includes welding to the surface of the substrate a plurality of wire segments to form a layer of upstanding weldments and then spreading the coating material between and over the weldments.
\patents\cap\spec\stel23ap.doc . _ The weldments are oriented in three-dimensional, jagged, irregular patterns which greatly increase the total surface area and hence the chemical and mechanical bond between the coating and the substrate.
Preferably, the coating material is malleable and curable to an altered, non-malleable state. For example, the coating material may be a granular material containing a bonding agent.
The lengths of the segments may be different and one end thereof may be fused with the material of the substrate.
The shape and profile of the weld deposits can be easily varied to provide the optimum support of the particular coating material depending on the service requirements. Once the coating material is pushed into the mesh formed by the welded wire segments, the weld and coating work together to provide mutual support. The additive materials may be wear prevention materials, friction enhancing or reducing materials, impact-absorbing materials, etc., that enhance the performanceof the substrate or provide some other desired benefit.
The weld deposits aid in supporting the coating material by spreading impact into substrate material and greatly decreasing the risk of delamination. The welded wire segments function much as reinforcing rod in concrete by helping to hold the bonded material together as well as to hold it by mechanical means to the substrate. The very rough surface of the weld deposits provides a full three dimensional interlocking grip of the coating material. The weld deposit improves the bonding of the coating when applied to overhead, or \patents\cap\spec\stel23ap.doc ~142543 vertical surfaces. The weld deposits also enable bonding of the coating in the presence of substrate contamination by oil, acids, etc. Advantageously, the process may be applied to worn, damaged or paper-thin surfaces of the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, as well as other features and advantages thereof, will be best understood by reference to the description which follows read in conjunction with the accompanying drawings, wherein:
Figure 1 is a schematic diagram showing the apparatus for welding wire segments onto a substrate;
Figure 2 is a plan view showing the serpentine pattern of the initial welding pass;
Figure 3 is a cross sectional view in elevation of the substrate taken along the line 3-3 of Figure 2 after the first pass; and Figure 4 is a cross sectional view in elevation of the substrate taken along the line 3-3 of Figure 2 after the second pass of welding and after the coating has been applied.
DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS
Referring to Figure 1 there is shown the apparatus used for welding on wire segments to a substrate 28. A suitable such apparatus is a Lincoln Wirematic 250 supplied by Lincoln Electric Company. A
welding power supply 10 is connected to a wire driver 12 \patents\cap\spec\stel23ap.doc 2142~43 ~_ - 8 -that has a pair of drive rollers 18 that grip wire 16 from a spool 14 and drive it through a center of cable 20 coupled to the wire driver 12. Near the end of cable 20 there is mounted a lever 22 which activates the drive rollers 18. To the exit end of cable 20 a replaceable contact tip 24 is inserted which serves to conduct current which passes down cable 20 through a braided copper conductor 23, shown only schematically, to wire 16. The wire 16 exits from the contact tip 24. Wire end 26 which has exited from cable 20 extends down to metallic substrate 28. Metallic substrate 28 is grounded to the power supply 10 through clip 30 and ground line 32.
As wire 16 is fed through the cable 20 and past the contact tip 24, the voltage applied between the wire 16 and the substrate 28 causes a discharge at the tip of the wire which melts a segment of the wire end 26 and a local portion of the substrate resulting in the formation of a weldment which fuses with the metal of the substrate 28. As the length of end 26 is increased, the voltage of the power supply 10 must be increased slightly to compensate for the slightly longer length of wire end 26.
As the speed of the wire feed rollers 18 is increased, the voltage must also be increased in order to create a hotter arc that will melt the wire and substrate faster.
The precise combination of speed, voltage, wire size, and length of wire end 26 must be selected for the result desired.
Initially a pass is made which applies a coating of weldment in a serpentine pattern as shown in Figure 2. This layer fuses with the substrate 28 and provides an intermediate layer 34 of a desired thickness typically less than 1/2 inch as shown in cross section in Figure 3. As shown in Figure 3, the intermediate layer 34 is applied in a way that produces an irregular \paten~ts\cap\spec\stel23ap.doc ~142~4 3 topography. The method produces only limited localized heating of the substrate and therefore produces minimum warpage or intrusiveness. It can be applied to thin substrates not capable of supporting convention welding without "burn-through" or severe warpage. Moreover, the localized heating flashes off any oil or other contaminant and allows the technique to be used on a degraded or contaminated surface. The matrix of weldments can also easily be formed on a vertical or overhead surface.
Once the intermediate layer 34 is formed, a second step involves welding on segments of wire which form upstanding weldments 38 as shown in Figure 4. With the entire substrate surface covered with such weldments, the final step involves the application of a malleable uncured coating of desired material. A wide variety of coating materials are possible such as ceramics bonded with epoxy, urethanes, concrete, carbides, etc. In fact any material that is malleable in its uncured state and cures to a substantially non-malleable state may be used.
The malleable uncured coating material is worked in between the weldments and over the substrate to a desired thickness in which all of the weldments are covered.
The matrix of weldments can be easily formed on a vertical or overhead surface. The length of wire end 26 measured from its tip to the end of the contact tip 24 may be from 1/2 to 8 inches in length.
After curing, the coating 40 forms a strong interlocking mechanical bond with the substrate 28. The resultant composite structure is shown in Figure 4.
Obviously, the need to weld wire to the substrate 28 limits the substrate material to a weldable metal.
\patents\cap\spec\stel23ap.doc ~142543 Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modification or embodiments as fall within the true scope of the invention.
\patents\cap\spec\stel23ap.doc
Claims (19)
1. A method of coating a substrate capable of being welded, comprising:
(a) welding segments of wire onto the substrate to form a plurality of upstanding weldments;
(b) coating between and around the weldments and over the substrate with an uncured coating material;
and (c) curing the coating material.
(a) welding segments of wire onto the substrate to form a plurality of upstanding weldments;
(b) coating between and around the weldments and over the substrate with an uncured coating material;
and (c) curing the coating material.
2. A method according to claim 1, wherein the coating material is malleable and capable of being cured to a substantially non-malleable stable state.
3. A method according to claim 1, wherein the welding is by electric arc welding of the wire onto the substrate.
4. A method according to claim 1, wherein the welding is done by positioning a wire segment protruding one-half to eight inches from a wire feed cable contact tip against a substrate.
5. A method according to claim 2, wherein the coating material is epoxy.
6. A coated material having a substrate, a plurality of wire segments welded to the substrate to form upstanding weldments and a coating of a cured material over the substrate and between and around the weldments.
7. A method of coating a substrate capable of being welded, comprising:
(a) welding segments of wire onto the substrate to form a first layer of weldment fused with the substrate;
(b) welding segments of wire onto said first layer to form a porous, three-dimensional matrix of upstanding weldments of varying height;
(c) coating between and around the weldments and over the substrate with an uncured coating material;
and (d) curing the coating material.
(a) welding segments of wire onto the substrate to form a first layer of weldment fused with the substrate;
(b) welding segments of wire onto said first layer to form a porous, three-dimensional matrix of upstanding weldments of varying height;
(c) coating between and around the weldments and over the substrate with an uncured coating material;
and (d) curing the coating material.
8. A method according to claim 7, wherein the coating material is malleable and capable of being cured to a substantially non-malleable, stable state.
9. A method according to claim 7, wherein the welding is by electric arc welding of the wire onto the substrate.
10. A method according to claim 7, wherein the welding is done by positioning a wire segment protruding one-half to eight inches from a wire feed cable 12 against a substrate, applying a voltage between said protruding wire and said substrate sufficiently high to create an arc and melt an end segment of said wire and fuse it to said substrate and continuously driving said wire through said cable so that wire segments are repeatedly and successively welded to said substrate.
11. A coated material having a substrate, a plurality of upstanding weldments welded to the substrate and a coating material over the substrate and between and around the wire segments.
12. A coated material according to claim 11, wherein the coating includes a material which is malleable in its uncured state but becomes substantially non-malleable in its cured state.
13. A coated material according to claim 11, wherein said weldments form a three dimensional porous matrix over the substrate fused with the material of said substrate.
14. A coated material according to claim 11, wherein the coating material is a surface conditioning material for imparting to the surface of said coated material a desired property.
15. A coated material according to claim 11, wherein the coating material is a material having a high surface friction.
16. A coated material according to claim 11, wherein the coating material is a low surface friction material.
17. A coated material according to claim 11, wherein the coating material is a sealant.
18. A coated material according to claim 11, wherein the bonding agent is epoxy.
19. A coated material according to claim 11, wherein said coated material is resistant to abrasion.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US19908994A | 1994-02-22 | 1994-02-22 | |
| US08/199,089 | 1994-02-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2142543A1 true CA2142543A1 (en) | 1995-08-23 |
Family
ID=22736165
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2142543 Abandoned CA2142543A1 (en) | 1994-02-22 | 1995-02-15 | Coated substrate and method of coating same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2142543A1 (en) |
-
1995
- 1995-02-15 CA CA 2142543 patent/CA2142543A1/en not_active Abandoned
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