Thermal spray coatings are used in many different industries, and the way they’re applied depends on what the part needs to do. The process uses a heat source, like a flame or plasma, and a coating material that comes as powder or wire. The material is heated until it melts into tiny droplets, which are then sprayed at high speed onto a surface. As the droplets hit, they stick and build up a protective layer.
What happens during thermal spraying
Thermal spraying is a general name for a group of coating methods that all work in a similar way. The melted particles hit the surface and flatten out and form thin layers that overlap and join together. This creates a strong coating that sticks to the surface rather than soaking into it.
Common spraying methods
Some of the most common methods of thermal spray coating, like the examples seen here, www.poeton.co.uk/surface-treatments/thermal-metal-sprays/, include HVOF spraying for strong coatings and plasma spraying. Arc-wire and flame spraying are also used, if a lower-cost option is needed.
Where it’s used
Thermal spraying is used in industries like aerospace, car manufacturing, rail and energy. It helps protect parts from wear, heat and corrosion, and it’s also a practical way to repair and extend the life of equipment.
Benefits of the process
A wide range of materials can be used, including metals, ceramics and plastics. Coatings can be applied thickly and very quickly, without causing heat damage to the original part. It’s also useful for repairing worn components, which is often much cheaper than replacing them completely.
