A Brief Overview of Thermal Spray Coating Processes

Thermal spray coating involves a technique in which a source of heat is used with material that melts and then is used to coat the surface of the workpiece. There are many different types of coating processes, and each can be useful depending on the project and industry.

Different Types of Thermal Spray Coating Processes

There are multiple kinds of thermal spray coating processes that are commonly used today. These can be used to protect material from extreme heat, corrosion, chemicals, and also environmental conditions.

Combustion Flame Spraying – This form of coating involves using a low-temperature flame heating material such as wire or powder to coat the workpiece. This method is cost-effective and commonly used.

Plasma Spraying – Another form is the use of plasma spraying. This method uses a plasma torch to heat and apply the coating. Powder is most typically used as the coating material. This method is advantageous when applying to objects with a very high melting point, and the final coating is much more durable than many other coating processes. It, naturally, is often more expensive as well.

High-Velocity Oxy-Fuel Spraying – This method uses a torch design that allows for the expansion of the flame. This creates more evenly-applied coating along with a thinner coat. Unlike plasma spraying, high-velocity oxy-fuel spraying can be used on materials with a low melting point.

The Importance of Using Thermal Spray Coating

The use of thermal spray coating can be a cost-effective way of increasing the longevity of the coated materials. It can be used to combat the negative long-term effects of extreme temperature conditions.


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