An HVOF extension gun for spraying internal diameters down to 5” (127 mm) has been developed and evaluated. The spray gun utilizes vortex stabilization of the flame which permits operation with a minimal length combustion chamber. Small spray distances and subsequent reduced particle dwell times present a challenge for heating and accelerating powders to achieve typical HVOF coating benchmark properties such as hardness, density and residual stresses. Initial coating characteristics and process/system capabilities are discussed.

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