Six thermal spray processes

Thermal spraying is a type of industrial coating process where metallic or ceramic materials are heated to a liquid, and sprayed onto surfaces to restore and protect them.

For expert help with thermal sprays, specialists such as www.poeton.co.uk/surface-treatments/thermal-metal-sprays/ can advise. There are several thermal spray processes.

HVOF

HVOF thermal spraying, or high velocity oxy-fuel, is arguably the most common according to Science Direct. It can be sprayed to an exceptionally thin layer, around 3/100 of an inch, but is durable and used to repair machinery.

HVAF

HVAF or high velocity air fuel is similar to HVOF, but produces a more uniform, stronger coating. It’s often chosen because it’s the most resistant to abrasion and corrosion.

Plasma Spray

Plasma spray is a high heat thermal spray system used to apply ceramic coatings, ideal for high temperature environments or objects subject to considerable wear and tear.

Spray and Fuse

This thermal spraying system uses high heat to fuse the coating and surface metallurgically, essentially melding the coating material and the product surface into one material.

Arc Spraying

Arc spraying is particularly suited to repairing shafts and improving the electrical conductivity of machinery parts. It uses heat and electricity to melt wire material. Air jets send the coating at speed onto the surface. The main advantage is that it’s quick, and cost effective.

Flame

Arguably the oldest method of thermal spraying is flame spraying, ideal for restoring damaged machinery parts, and uses oxygen to spray wire or powder materials.