It would be best to remember that thermal spray is the advanced technology that will help you repair incorrectly machined parts and worn components, which is the main reason for its popularity.

A hundred years ago, maintenance personnel and plant superintendents relied on affordable thermal spray technology to deal with heavy industrial equipment with ease.

Since that time, thermal spray materials and equipment have advanced to a point where this particular technology is an excellent method of creating new materials and systems.

Today, you can find numerous coating solutions depending on your needs and preferences, which you should remember beforehand.

We can differentiate four processes for thermal spraying, including HVOF (high-velocity oxygen fuel), plasma, arc, and flame.

What is Thermal Spray Technology?

Similarly, as chromium plating and overlay welding, you should know that this particular process is all about coating and fixing specific damage.

It uses feedstock material such as powder or wires, which you have to soften and melt by electricity or flame, and use it on a particular work piece.

However, to produce a proper coating, the torch has to traverse a particular piece to ensure its efficiency. Like other industrial processes, you should know that this specific coating option comes with specific benefits and disadvantages.

It is vital to learn about different features and characteristics, which will help you use this particular method of coating with ease.

Benefits of Thermal Spray

  • Processing Speed – When it comes to processing speed, you should know that it depends on the material you wish to use and the system. Therefore, you can create between half and two pounds of material on square feet per 0.01-inch thickness, which is essential to remember.
  • Versatility – Besides, you can use it for any plastic, ceramic, and metal work

piece, which makes it highly versatile compared with other options.

  • Low-Heat – You can use this particular process to prevent a component’s thermal history, which will provide you with low heat input.
  • Affordable Price Tag – One of the most significant advantages of this particular coating method is repairing certain industrial machinery with ease, which will prevent a need to purchase a new one. In most cases, this specific coating will last much longer than other options.

By checking here, you can learn more about thermal spraying.


It would help if you remembered that the flame-spraying process requires a fuel gas such as propylene, propane, or acetylene combined with oxygen. Then you can feed it into a torch with an idea to create a proper flame.

The next step is to inject wire or powder into the flame, which will melt on a particular work piece, and you will get new and more durable material than the original. In most cases, people use this specific method onsite or in the shop because it comes with a low price tag.

You can apply materials, including Hastelloy alloys, nickel aluminides, stainless still, tin-based alloy, and tin. Since it features low velocity, you should know that flame would create a considerable and thicker coating than the original material.

Therefore, the coating will be more oxidized and porous than other spraying options you can choose. You should know that porosity is beneficial if you need a particular lubricant such as oil, which will enter the coating and increase a specific component’s durability.

On the other hand, oxides will enhance water resistance and thickness, something you should understand.


When it comes to arc spraying, you will need two wires that are creating a proper contact. The electricity load will cause wires to melt after they touch each other.

You will also need an atomizing gas such as nitrogen or air to strip the material from the wires and place it on particular machinery you wish to repair.

As you can see from the method, arc spraying is an affordable option, and you can use it both off and on-field, depending on your needs and requirements. Since it uses low particle velocities, you can create a significant thickness for a material you wish to use.

The most common materials are bronze, aluminum, zinc, nickel aluminides, and stainless steel. In the last few years, a nozzle has advanced to a point where you can enjoy perfect spray pattern, coating quality, and control while using it.

You can use a coarse spray to create a more substantial thickness, while the fine method will provide you both a dense and smooth finish.

As soon as you watch this video: you will learn more about this particular coating technology.


If you wish to choose the most versatile option for thermal spraying, we recommend you choose this particular one.

The operation requires gases such as hydrogen or argon and a proper torch. Electricity will ionize and dissociate gases, while atomic components will combine to provide you the exceptional heat.

You should know that temperatures could easily reach ten thousand degrees Celsius, which will make any metal material into plasma; you can use it to create a thick coating with ease.

By Master