KR100328314B1 - High-Velocity Thermal Spray Apparatus and Mehtod of Coatings or Bulk Materials with the Same - Google Patents

Abstract

The present invention relates to a mixing assembly comprising: a mixing assembly configured to mix an oxidant gas and a fuel; An internal burner for burning the mixture of oxidant and fuel; An ignition device for starting combustion of the mixture; A gas expansion nozzle configured to receive combustion products of the mixture and form a high velocity gas jet; A mass transfer unit configured to transfer a predetermined soluble material into the jet to form a flow of heated particles accelerated below the melting point of the soluble material by the jet, and increase the pressure and flow rate of the oxidant or the fuel. A high speed thermal spray that deposits material onto a substrate that further includes a catalyst subsidiary located in the internal burner that, when added to the mixture, or when adding an inert gas into the mixture, lowers the combustion temperature of the mixture below the melting point of the molten material. The device is starting.

Description

High-Velocity Thermal Spray Apparatus and Mehtod of Coatings or Bulk Materials with the Same}

BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to flame spray devices and methods of depositing coatings and bulk materials using thermal spraying techniques, and in particular high speed oxidant-fuel spray devices and their It is about a method. Thermal spray technology when oxygen is used as oxidant is called HVOF (High-Velocity Oxygen-Feul) spraying, and thermal spray technology when air and oxygen-rich air is used as oxidant is HVAF (High-Velocity Air). -Fuel) Called a warrior.

Thermal spray technology is widely used to apply metals and ceramics in the form of coatings and bulk materials to various types of substrates. Most thermal spray methods utilize the energy of hot gas jets to heat and accelerate particles of the spray material. When the particles collide with the substrate, the particles form a coating.

HVOF devices typically generate hot gas jets by burning fuel and oxygen in a high pressure internal burner in the form of several rods. The fuel may be a gaseous fuel such as propane, methane, propylene, MAPP gas, hydrogen, or a liquid fuel such as kerosene. The gas expands in an exhaust nozzle or barrel at sonic velocity. Inflation in the atmosphere or in an enlarged cross section of a nozzle (eg, Laval's nozzle) forms a supersonic jet. For this reason, it is called 'high-velocity'. Such a device is shown in US Pat. Nos. 4,342,551 and 4,343,605, registered in August 1982. U.S. Patents 4,370,538, 4,540,121, 4,634,611, 4,836,447, 5,019,686, 5,206,059, and 5,535,590 are HVOF guns designed to improve the efficiency of heating and accelerating spraying material. And improved inventions. Despite the denser coating, because the particles at least partially melt in the HVOF process, materials with higher oxygen content are deposited in the HVOF process, thus making the surface of the particles very active. Since the jet always contains oxygen gas due to incomplete combustion and the release of air from the atmosphere, the surface on which the particles are fused oxidizes quickly. In addition, these processes consume large amounts of compressed oxygen and are economically expensive. In addition, the molten molten particles can block the long nozzles, and thus many problems arise in operating the HVOF apparatus.

The HVAF device of US Pat. No. 5,120,582 is an economical alternative to the HVOF process. Combustion of air and kerosene is the main mode of operation of these devices. U.S. Patent Nos. 5,405,085 and 5,520,334 show more advanced designs. The main problem with these devices is that the flame propagation rate in the fuel-air mixture is two orders of magnitude lower than in the fuel-oxygen mixture, resulting in unstable combustion when the gas flows at high speed. Although a burner with a wider interior is used to perform a stable and complete combustion, this has the problem that the chamber is too long so that the powder, ie particles, do not pass in the axial direction of the chamber and nozzle. In order to solve this problem, injecting particles to the nozzle side may cause a larger problem, such as clogging of the nozzle, in an HVOF apparatus using axial injection. For the ignition of combustion, the use of hydrogen and methane as the pilot flame of the HVAF gun can render the gun impractical and unsafe.

U. S. Patent No. 5,932, 293 has made significant improvements in the design of the HVAF device. Permeable burner blocks were introduced into the internal combustion chamber. The hot walls and passages of the permeable burner block continue to ignite the mixture when heated above the autoignition temperature of the air-fuel mixture, thus performing stable combustion in the small burner. However, stable combustion is carried out only in a narrow range of fuel to air ratio, i.e., in a ratio close to the stoichimetrical ratio, and the total flow of gas is such that the flow of gas causes the permeable burner block to cool. Is limited. This obviously not only limits the width of the technical parameters required for the dissolution of different materials, but it can also cause technical problems when the droplets of liquefied fuel go to the burner and use propane or heavier fuels. It always happens. Droplets of fuel evaporate rapidly at the burners, reducing the air-to-fuel ratio and making combustion unstable.

When the combustion temperature (1900 ° C for a mixture of propane and air) exceeds the melting point of most soluble materials, the HAVF coating is more oxidized, so that at least the surface of the soluble particles melts and is actively oxidized by oxygen in the jet. do.

On the other hand, when the solid non-liquefied particles are dissolved, the oxidation of the material during the melting is substantially suppressed. U.S. Patent 5,302,414 discloses a gas-dynamic spray method of applying a coating. In this method, a supersonic jet is made by expanding compressed gases having a temperature lower than the melting temperature of the soluble material. The coating is formed while the solid particles collide, and since the solid particles are not heated, they are not substantially oxidized during deposition. However, the coating formed by the unheated particles is porous compared to the coating of HVOF. Preheating the compressed gas with an electric heater increases the volume of the device, while yielding no significant effect on the quality of the coating.

The use of HVOF and HVAF techniques can make particles look more effective because they can be accelerated and heated below the melting point of the soluble material. This view was published in December 1992 in US Patent No. 5,271,965, as well as on page 289 of the Technical Note of the Thermal Spray Technology Journal. He assumed that the solid particles melted due to the release of kinetic energy (collision melting) while colliding with the substrate. Therefore, particle velocity has become a very important factor in the formation of the coating. The problem is that in known HVOF and HVAF apparatus, the reduction of the gas temperature in the burner always involves the reduction of the gas velocity. This results in a decrease in particle speed. To overcome the above problems, unique solutions have been derived. For example, to keep the solid state while the particles melt, US Pat. No. 5,330,798 proposed to inject droplets to cool the jet of the nozzle below the melting point of the material. The combustion process itself is then not affected. The problem with this apparatus is that the process is complicated and the efficiency of the apparatus is reduced.

In addition, the decrease in gas velocity due to the temperature drop has caused a problem of high quality coating deposition by melting solid particles with HVOF and HVAF techniques. Indeed, it is impossible to implement in the known apparatus the necessary lowering of the gas temperature without causing destabilization of the combustion. As is known, the stable combustion of the oxidant-fuel mixture in a state where the gas flows at high speed is performed only in a range where the ratio of the oxidant-fuel close to the stoichimetrical ratio is narrow. The maximum temperature of combustion is reached in this range. For example, for a mixture of oxygen and propane, the stoichiometric ratio is about 5: 1 by volume and the maximum combustion temperature exceeds 2800 ° C. Excessive oxygen lowers the combustion temperature. For oxygen and propane, the combustion temperature is about 2500 ° C at a ratio of 2.5: 1. Increasing the oxygen content renders combustion impossible. In the case of an oxygen-propane mixture, the stoichiometric ratio has a maximum combustion temperature of about 1900 ° C. and a volume of about 25: 1. Even when there is a 'hot' wall of the permeable burner block, when the stoichiometric ratio flows above 10%, this mixture does not allow combustion (US Pat. No. 5,932.293). Therefore, in the HVAF process, it is substantially impossible to decrease the gas temperature by increasing the content of air or propane above the stoichiometric ratio. The gas temperature mentioned above is preferably above the melting point of most of the commercially available alloys used for thermal spraying. Thus, the surface of the melt particles melts at least, allowing the material to oxidize quickly during melting. The problem may be exacerbated when fine particles, for example particles smaller than 20 μm, are used.

It is an object of the present invention to provide an apparatus and method for melting low dissolving particles having a particle velocity close to that of a gas jet to form low oxidation, high density coatings and bulk materials.

1 is a schematic vertical cross-sectional view of a high speed thermal spray apparatus according to a first preferred embodiment of the present invention having a catalyst member in the form of a wire-net insert forming an internal burner.

FIG. 2 is a schematic vertical cross-sectional view of a thermal spray apparatus, which is a variation of the first preferred embodiment of the present invention having a catalyst member in the form of a wire-net insert.

Figure 3 is a schematic vertical cross-sectional view of a high speed thermal spray apparatus according to a second preferred embodiment of the present invention having a passage of a catalyst ceramic support for forming an internal burner and a catalyst member coated on the lower surface.

<Description of the symbols for the main parts of the drawings>

1: fuel supply tube 2: powder injector

3: air supply tube 5: air distributor

6: mixing block 8: catalyst member

A: air distribution chamber B: cooling part

C: bore D: cooling passage

E: Air Bore F: Mixing Chamber

G: Mixture Outlet Bore H: Chamber

In order to achieve the above object, a thermal spray device according to a preferred embodiment of the present invention comprises an oxidizer-fuel mixture assembly, an internal burner, an ignition device, an expansion nozzle, and a soluble material transfer unit. In addition, the thermal spray apparatus according to the present invention is designed to reduce the combustion temperature of the mixture below the melting point of the soluble material when the pressure and the flow rate of the oxidant or fuel are increased above the stoichiometric ratio, or when an inert gas is added to the mixture. It further comprises a catalytic member in the internal burner.

In the present invention, the catalyst member of the internal burner satisfies at least two main functions as follows. First, it significantly lowers the ignition temperature of the oxidant-fuel mixture. Thus, it is possible to significantly increase the total flow rate of the gas without 'supercooling' the catalyst surface igniting the combustible mixture. Second, the catalyst member absorbs reactive gases on the surface of the catalyst that react (burn) at a particular concentration of gas. If the catalyst surface is sufficiently wide, it is possible to enhance combustion at the desired oxidant-fuel ratio. Thus, in the presence of a catalyst, the pressure and flow rate of the oxidant or fuel can be increased above the stoichiometric ratio, and it is possible to add an inert gas such as nitrogen to the mixture. Thus, the gas can be cooled to a predetermined temperature without destabilizing combustion. On the other hand, when a catalytically internal burner is used to increase the total energy of the jet, the pressure and flow rate of the oxidant and fuel of the high melting point oxidant are substantially increased.

One important factor is that as the pressure and flow rate of the gas increases, the temperature drop and the drop in gas velocity in the nozzle are effectively compensated. In addition, the concentration of gas is increased. As a result, the velocity of the dissolved particles does not decrease with decreasing temperature. On the other hand, it significantly increases when the following two conditions of the particle velocity are satisfied. First, to melt the fine particles of 1 ~ 20㎛ or less. These particles can be accelerated up to the velocity of the gas jet. Second, the use of long nozzles that can accelerate particles without clogging the nozzles by solid particles. In a preferred embodiment of the present invention, the particle velocity when using an air-propane heating mixture is at least 600 m / s-800 m / s.

In the apparatus and method according to a preferred embodiment of the present invention, the catalyst member is a catalyst selected from the group of noble metals such as platinum, palladium, rhodium, or the precious metals. At least one binary oxygen of rare earth metals (Ce, La, Nd) or at least one binary oxygen formed by barium, strontium and rare earth metals, or at high temperature oxidation And a catalyst capable of withstanding and lowering the ignition temperature of the oxidant-fuel mixture used.

The catalyst element can be made in the form of a wire-net insert, and also at least one porous ceramic support positioned on the inner burner or on the coating of the walls and passages of the inner burner instead of the wire-net insert. It can also be made as a coating of. Catalytic coating can only be applied to the surface where combustion is to be performed, thus causing local combustion only in the required area and protecting the other surface of the burner from overheating.

The high speed thermal spray apparatus may also include at least one or more second internal burners and at least one or more second expansion nozzles of annular geometry surrounding the first expansion nozzle. This 'casecade' of burners and nozzles is configured to further accelerate the particles and to heat the particles relatively slowly and evenly below the melting point of the melt.

The material transfer unit according to the preferred embodiment of the present invention can transfer powder or wire into the device. In the case of powder stock, the material transfer unit comprises at least one injector to transfer the powder particles into an internal burner and / or expansion nozzle located at a predetermined position. The powder according to a preferred embodiment of the invention is injected in the axial direction of the internal burner, so that the heating and acceleration efficiency is maximized.

In the case of wire stock, the material transfer unit is a dual-wire configured to transfer the melt melted by the electric arc wire tip in the direction of the axial or expansion nozzle of the internal burner. A) Electric arc device. In the apparatus and method according to a preferred embodiment of the invention, the molten wire is subdivided into fine particles, accelerated and cooled by a high velocity gas jet formed by the combustion of the excess oxidant-fuel mixture. A flow rate higher than the stoichiometric ratio is necessary not only to reduce the gas temperature below the melting point of the soluble material, but also to reduce the influence of the environment in the jet, thus inhibiting possible oxidation during melting. The more the coating is applied with a cold jet, the shorter the distance between the nozzle and the substrate, and the jet is less diluted with the air blown out of the atmosphere, which makes it possible to more efficiently inhibit oxidation, not caused by burned fuel.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

As shown in FIG. 1, the thermal spray apparatus according to the invention is operated by an air-gas fuel mixture. According to a preferred embodiment of the present invention, a thermal spray apparatus includes a mixing assembly formed by a fuel supply tube 1, an air supply tube 3, an air distributor 5, and a mixing block 6. Has) The thermal spray apparatus of the present invention also has a catalyst burner formed by the catalyst member 8 made as a wire-net insert of the chamber H. The lower part of the chamber H serves as a collector of the gaseous products of combustion. The gas collector housing 9 surrounds the lower part of the chamber. The thermal spray apparatus of the present invention includes a gas expansion nozzle 10 and a mass transfer unit in the form of a powder injector 2. The respective components are assembled in a cylindrical body consisting of a main body housing 7, a main body rear housing 4 and a nozzle housing 11.

In a preferred embodiment of the invention, the compressed air enters the air distribution chamber (A) through the air supply tube (3). Part of the air enters the cooling section B through the distributor bore C, and then enters the cooling passage D to cool the thermal spray apparatus. Some of this air flows out of the thermal spray apparatus through the nozzle cooling passage D1, forming an annular stream around the main gas jet.

The other part of the air flows from the air distribution chamber A to the mixing chamber F through the air bore E of the mixing block 6. Gas fuel such as propane or propylene is supplied to the mixing chamber (F) through the fuel supply tube (1). Due to the expansion of the compressed air from the small air bore (E) into the large mixing chamber (F), the air ejects the fuel forming the air-fuel mixture. Through the mixture outlet bore G of the mixing block 6, the mixture flows into the chamber H with the catalyst member 8. The chamber (H) functions as a combustion chamber. The mixture is ignited with a spark plug or a glowing device (not shown) inside the catalyst member 8 to burn on the surface of the catalyst. As the gas burns, it forms a high velocity jet and expands to the nozzle 10. The jet reaches supersonic speed as it expands from the nozzle 10 into the atmosphere. Particles of the dissolved material are transmitted in the axial direction of the chamber (H) through the powder detector (2) through a carrier gas (carrier gas) such as compressed nitrogen. Particles flowing through the chamber H and the nozzle 10 are heated and accelerated by the combustion products of the gas jet forming the energized energy of the particles I. The particles impinge upon the substrate J to form a coating or bulk material.

In a preferred embodiment of the present invention, the catalyst member of the internal burner performs at least two main functions. First, the catalyst member significantly lowers the ignition temperature of the oxidant-fuel mixture. This mechanism is based on reducing the activation energy for the reaction between oxygen and fuel molecules by including the oxygen and fuel molecules in a reversible redox reaction on the catalyst surface. Thus, the total flow of gas can be increased significantly without 'supercooling' the catalyst surface igniting the heatable mixture. Secondly, the catalyst member absorbs reactive gases on the surface of the catalyst that reacts (burns) at a particular concentration of gas. When the surface of the catalyst is widened, it is possible to enhance combustion at the desired oxidant-fuel ratio. As a result, when the catalyst is present, it becomes possible to increase the pressure and flow rate of the oxidant or fuel above the stoichiometric ratio or to add an inert gas such as nitrogen, thus cooling the gas to a predetermined temperature without unstable combustion. Can be. In particular, in the case of combustion chambers of the same size, it is possible to increase the flow of air from 10 to 12 cubic meters per minute in the absence of a catalyst and 20 to 25 cubic meters in the absence of a catalyst while performing stable combustion. Therefore, it is possible to lower the jet temperature from 1900 ° C to 1000 ~ 1200 ° C. Of course, it is possible to increase the pressure and flow rate of the oxidant and fuel through the catalyst burner, thus increasing the total jet energy. It is also suitable for the melting of high melting point materials such as refractory metals or titanium alloys.

The increase in gas pressure and flow rate effectively compensates for the loss of velocity of gas in the nozzle as the temperature drops. And the density of the gas also increases. As a result, the velocity of the dissolved particles does not decrease with the decrease in temperature. On the other hand, it significantly increases when the two conditions following the particle velocity are met. The first condition is to melt fine particles of powder material of 1-20 μm or less that can be accelerated at the velocity of the gas jet. The second is to use nozzles with a length that can accelerate the particles without clogging the nozzles due to solid particles.

In a preferred embodiment of the present invention, the catalyst member is a catalyst selected from the group of noble metals such as platinum, palladium, rhodium, or the noble and rare earth metals. At least one binary oxygen of Ce, La, Nd, or at least one binary oxygen formed by barium, strontium and rare earth metals, or an oxidant-fuel mixture well tolerated at high temperature oxidation and used It includes a catalyst that can lower the ignition temperature of.

The catalyst member may be made in the form of a wire-net insert, and also at least one porous ceramic support positioned on the inner burner or on the coating of the walls and passages of the internal burner instead of the wire-net insert. Can also be made as a coating. Catalytic coating can only be applied to the surface where combustion is to be performed, thus causing local combustion only in the required area and protecting the other surface of the burner from overheating.

As shown in FIG. 2, a high speed air-fuel device according to a preferred embodiment of the present invention includes a first (inner) expansion nozzle and a second internal burner having an annular shape around the second nozzle. The first burner and the nozzle operate as described above. The second chamber N is located between the outlet of the internal expansion nozzle 10 and the nozzle housing 11. In the second chamber N, the second burner is wrapped by an inner catalyst support ring 13 made of SiC-Al ₂ O ₃ ceramic and an outer catalyst support ring 14 made of Al ₂ O ₃ based ceramic. . The outer and lower sides of the inner ring 13 and the inner surface of the outer ring 14 are covered with a catalyst coating 17 such as platinum oxide or platinum-cerium oxide. The second expansion nozzle 15 is made of SiC ceramic and is fixed to the nozzle nut 16 in the nozzle housing 11. The fuel for the second burner is supplied through the second fuel supply tube 12 and mixed in the second chamber K with the cooling air coming from the cooling passage D. The mixture of air and fuel flows into the second burner through the second mixture outlet bore (L) in the form of a slot (M) surrounded by the catalytic reaction surface of the inner catalyst support ring (13) and the outer catalyst support ring. The mixture is ignited from the back-flash of the first gas jet expanding from the inner nozzle 10. The combustion product is mixed with a first jet that expands to a second nozzle and carries a stream of particles therein. This method provides a very 'soft' uniform heat to melt the particles and also has a great impact on the acceleration of the particles. In a preferred embodiment of the invention, the speed of the particles exceeds 600 m / s. In particular, in the case of an alloy 625-type powder having a length of 200 mm and an average particle size of 10 μm, the average particle velocity reaches 800 m / s when a heatable air-propane mixture is used. do.

As shown in FIG. 3, the thermal spray apparatus according to the second preferred embodiment of the present invention includes a main body 7 for fixing the internal catalyst support ring 9 made of SiC-Al ₂ O ₃ ceramic, and Al ₂ O. _It consists of an external catalyst support ring 8 made of _three -phase ceramic. The burner is in the form of a combustion slot D made between the two rings. While forming the slot D, the cylindrical surface of the two rings and the lower surface of the inner ring 9 are made of barium oxide, lanthanum oxide, or metallic platinum. It is covered with a catalyst coating 13. The main body rear housing 5 has two contacts for directing the cooling air supply tube 1, the heating mixture supply tube 4, and the two spraying wires 3 in the axial direction of the expansion nozzle 12. The tube 2 is fixed to the main body 7 while being fixed. The position of the contact tube 2 is adjusted by the positioner 11 located in the body. The collector housing 10 is mounted on the front face of the body 7, the outlet of which is made in the form of an expansion nozzle 12. The front of the main body 7 is covered with an air cap 6. The heatable mixture, for example the air-propane mixture, is fed through a tube 4 into a ring-shaped mixture distributor chamber C in the body 7. Thereafter, the mixture burns onto the surface of the catalyst coating 13 while passing through the combustion slot D. Spark plugs (not shown) are used for combustion. Unreacted gases burn on the lower surface of the inner ring 9 covered with a catalyst coating. The gaseous combustion products are directed to the collector chamber F by the collector housing 10 and then to the expansion nozzle 12. The gas jet expanding from the nozzle 12 reaches supersonic speed. Two consumable wires 3 for sparing are transmitted in the axial direction of the nozzle 12 via the contact tube 2 by a wire transfer mechanism L. The electric arc G supported by the power supply K for the arc mechanism melts a wire tip in the nozzle 12. The gas jet of the combustion product subdivides the molten wire tip into fine particles and accelerates to form an activated particle flow (H). When the particles collide with the substrate J, the coating I is formed. Combustion in the slot (D) is first to cool the gas jet of the combustion product below the melting point of the soluble material to effectively cool the granular particles, and second to prevent the soluble particles from oxidizing in the jet. In excess of fuel, above the stoichiometric ratio. In particular, in the case of an air-propane mixture, the use of a catalyst support member can increase the flow rate of propane 3-4 folds above the stoichiometric ratio without interrupting combustion. Cooling air is supplied to the air distribution chamber (A) through the tube (1). Through the cooling bore (B) of the main body (7), the cooling air flows into the cooling passage (E) between the air cap (6) and the collector housing (10) and forms an annular stream (nozzle 12). Leaving the device around. This flow surrounds the high velocity jet of gas while suppressing the release of oxygen from the atmosphere.

excuse

A coating of an alloy 671-type powder (Ni-based-43% Cr-0.5% -Ti-0.9% Si) with a particle size of 10-45 μm, as described in the preferred embodiment of FIG. It was fired through a device consisting of an internal burner and two nozzles. The catalyst member has a platinum catalyst coating, has a porosity of 64%, and is made in the form of a porous catalyst support ring made of SiC-Al ₂ O ₃ ceramic. The thermal spray apparatus was operated at a flow rate of 20 cubic meters per minute, an inlet pressure of 8.4 bar, a propane flow rate of 2 kg per minute, and a pressure of 5 bar. The total air flow was 70% higher than the stoichiometric ratio and lowered the exhaust gas temperature to about 1400 ° C. A 0.4 mm thick coating is a 1018 type carbon steel substrate made as a sample for adhesion strength measurement in accordance with ASTM C633 standard, a 75 x 25 x 6 mm coupon for coating structure investigation, and a coating gas according to ISO 4022 standard. To measure the permeability (coating gas permeability) was deposited on a porous stainless steel (316SS type) filter-sample having a diameter of 25 mm, a thickness of 6 mm, and a ball size of 2 μm. The apparent oxygen content and the apparent porosity of the coatings were measured on the cross section of the coupon using a metallographic image analysis method. The total oxygen content in the coating was measured by reducing melting in the flow of inert carrier gas (LECO Oxygen Analyzer). The total oxygen content in the powder stock material is 0.6%.

The following coating properties are obtained.

(1) Appearance porosity (%) measurement not possible

(2) Appearance oxidation content (%) measurement not possible

(3) Total oxygen content (%) 0.16

(4) Breathability (nm ² ) not available

(0.01 or less)

(5) Adhesive strength (MPa) 80.0 or more

(rupture through epoxy glue)

When the material is sprayed using known HVOF and HAF techniques, the oxygen content in the coating varies from 1.0 to 3.5 (%), which is a higher size grade in a heat spray device according to a preferred embodiment of the present invention. The air permeability (suitable for through porosity) of known HVOF and HVAF coatings is measured from 0.05 to 2.0 (nm ² ), which is significantly higher than the present invention.

Thus, coatings deposited according to a preferred embodiment of the present invention show better density and substantially lower oxygen content compared to known HVOF and HVAF techniques.

Claims (9)

A mixing assembly configured to mix the oxidant gas and the fuel; An internal burner for burning the mixture of oxidant and fuel; An ignition device for starting combustion of the mixture; A gas expansion nozzle configured to receive combustion products of the mixture and form a high velocity gas jet; A mass transfer unit configured to transfer a predetermined soluble material into the jet to form a flow of heated particles accelerated below the melting point of the soluble material by the jet Including, And further comprising a catalyst subsidiary located in said internal burner that reduces the combustion temperature of said mixture below the melting point of said soluble material when increasing the pressure and flow rate of said oxidant or said fuel, or adding an inert gas into said mixture. A high speed thermal spray apparatus for depositing a material on a substrate. The method of claim 1, The catalyst member may include a catalyst selected from the group consisting of at least one of noble metals such as platinum, palladium, and rhodium, or the noble metal and rare earth metal; At least one binary oxygen of Ce, La, Nd, or at least one binary oxygen formed by barium, strontium and the rare earth metal, or the ignition temperature of the mixture of oxidant and fuel A high speed thermal spray device comprising a high heat resistant catalyst that can be degraded. The method of claim 1, The catalyst member is made of a wire or a wire-net insert, a coating of the walls and passages of the inner burner, and a coating of at least one catalytic ceramic supporter located within the inner burner. The method of claim 1, A high speed thermal further comprising at least one annular second internal burner surrounding the expansion nozzle and at least one second nozzle configured to further accelerate the particles and uniformly heat the particles below the melting point of the soluble material; Spray device. The method of claim 1, The mass transfer unit includes at least one injector for transferring the particles of the dissolved material into the internal burner or the expansion nozzle located at a predetermined position. The method of claim 1, The mass transfer unit is a high speed thermal spray apparatus which is a double-wire electric arc device for transferring melt melted by an electric arc wire tip to an axial direction of the internal burner or to the expansion nozzle. Mixing the oxidant gas and the fuel in the mixing assembly; Igniting and burning the mixture of oxidant and fuel in an internal burner; Forming a high velocity gas jet of combustion products of the mixture in a gas expansion nozzle; Introducing a predetermined soluble material into the jet by a mass transfer unit to form a flow of particles accelerated and heated by the jet below the melting point of the soluble material; Including, When the pressure and flow rate of the oxidant or fuel increases above the stoichiometric ratio, or when an inert gas is added to the mixture, a catalyst in the distribution burner to lower the combustion temperature of the mixture below the melting point of the soluble material A method of forming a coating or bulk material by depositing material onto a substrate using a high speed thermal spray apparatus, further comprising using a subsidiary agent. The method of claim 7, wherein Incorporating the soluble material into the high speed thermal spray apparatus in the form of undissolved powder in the jet. The method of claim 7, wherein Wires, rods, while subdividing, accelerating and cooling the dissolved material by the jet with an excess amount of fuel in the burner and gas expansion nozzles to inhibit oxidation that may occur during the formation of the coating or bulk material. introducing the molten material into the high speed thermal spray apparatus in the form of a melt by means of an electric arc tip of a rod.