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What is Thermal Spray ?
Thermal spray refers to a collection of coating techniques where materials—typically metals, ceramics, cermets, or certain polymers—are introduced into a spray gun in the form of wire, powder, or rods. These materials are heated to temperatures at or slightly above their melting point. The molten or semi-molten particles are then propelled toward the target surface by a stream of gas. Upon striking the surface, the heated particles rapidly cool and solidify. As additional particles continue to hit and layer onto the surface, the coating builds up in thickness. The particles flatten into thin overlapping platelets that bond to the surface and to each other as they harden. Achieving the desired coating thickness typically requires several passes of the spray tool. The equipment used in these processes is often referred to as spray guns or torches.
Advantages of Thermal Spray
Versatility: One of the primary advantages of thermal spray technology is its versatility in terms of material selection. Virtually any material that can be melted without decomposing can be used for coating applications, allowing for a wide range of coating compositions and properties.
Low Heat Input: Unlike traditional coating methods such as welding or brazing, thermal spray processes typically do not significantly heat the substrate. This allows for the application of coatings onto heat-sensitive materials or fully heat-treated components without compromising their properties or dimensional integrity.
Repairability: Thermal spray coatings can often be stripped and recoated without altering the properties or dimensions of the underlying substrate. This makes it an ideal choice for repairing worn or damaged coatings, extending the service life of components and minimizing downtime.
Selection of the appropriate thermal spray method is typically determined by:
The Process Basics
All thermal spray techniques involve projecting tiny molten particles onto a properly prepared surface, where they adhere and form a uniform coating. To produce these molten particles, a combination of a heat source, coating material, and a method of atomizing and projecting the material is necessary. Upon impact, the particles flatten, rapidly solidify, and bond mechanically—first to the roughened base surface and then to each other as the coating accumulates.
Thermal spray equipment is generally categorized into four primary types: Powder Flame Spray, Combustion Wire Flame Spray, Twin Wire Arc Spray, High Velocity Oxygen Fuel (HVOF), and Plasma Spray.
Visit each process page to learn more about the individual technologies.