Five Common Thermal Spray Coating Processes

Thermal spray coating processes encompass a range of techniques used to apply protective coatings. Below are 5 methods which offer unique advantages and applications, making them vital in modern engineering and manufacturing.

1. Flame Spray Coating

Flame spray coating involves melting metallic or ceramic materials in a combustion flame and propelling them onto a substrate using compressed air. This process is versatile and cost-effective, suitable for applications such as corrosion protection and restoring worn-out parts.

2. Arc Spray Coating

Arc spray coating utilises an electric arc to melt metal wires, which are then atomised and propelled onto a surface by compressed air. This method produces dense, uniform coatings with excellent adhesion, making it ideal for applications requiring high wear resistance and dimensional restoration.

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3. Plasma Spray Coating

According to Hayden Corp plasma spray, also known as thermal plasma spray, employs a high-temperature plasma flame to melt and propel coating materials onto a substrate. This process allows for precise control over coating properties such as thickness, composition and microstructure, making it suitable for thermal barrier coatings and aerospace applications.

For those who are interested in learning more about the advantages of plasma coatings and their advanced treatments, contact a specialist such as https://www.poeton.co.uk/advanced-treatments/apticote-800-thermal-plasma-spray/.

4. High-Velocity Oxy-Fuel (HVOF) Coating

HVOF coating involves heating coating materials in a combustion chamber and accelerating them to supersonic speeds using a mixture of oxygen and fuel gases. This process produces dense, tightly bonded coatings with low porosity and high hardness, offering superior wear and erosion resistance in harsh environments.

5. Cold Spray Coating

Cold spray coating uses compressed gas to propel fine powder particles at high velocity onto a substrate where they deform and adhere without melting. This method is suitable for coating heat-sensitive materials and producing thick, dense coatings with minimal substrate heating.

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