Does Thermal Spray Work?
materials are fed into a “gun” where they are heated
to a molten or semi-molten state by electric or combustion energy.
gas/air atomizes and propels the heated particles to a substrate
that has been cleaned and prepped by abrasive grit blast. The
heated particles impact the surface and flatten, which bonds
them to the substrate where they build to create a dense, tightly-bound
Benefits of Thermal Spray Coatings
variety of materials
adherence to substrate
corrosion or wear resistance
welded overlays have been used for many years, improvements in
Thermal Spray equipment and process controls offer bond strengths
and thickness potentials that rival welding. Added benefits of
thermal spray are the relative smooth and consistent surface
finish “as sprayed” allowing for quicker and more
efficient post-processing to final size. Additionally, there
is no heat affected zone (HAZ) associated with thermal spray.
Because of the limited temperature exposure of thermal spray
(<300°F), substrate strength and temper characteristics
are not altered.
Surface Technologies’ High Velocity Oxygen Fueled (HVOF)
coating method uses tightly controlled processing to apply an
array of coatings, such as tungsten or chromium carbide, in place
of hard chrome.
of the HVOF benefits are:
solutioning of carbides
or compressive stress
band strength >10,000 psi.
Thermal Spray Coatings adhere to a wide variety of substrates.
Their low permeability provides long-lasting protection against
corrosion and wear. Thermal spray coating methods include HVOF, Plasma, Flame Spray and Electric Arc.
Flame Spray – a low cost, mature
Plasma Spray – combines gases and
electrical power to achieve high temperature
capabilities with a broad base of materials,
Electric Arc – a high capacity, medium
cost technology good for a wide range of
HVOF – state-of-the-art, high velocity
process of dense, well-bonded surface