Industrial thermal spray processes are used to apply protective coatings to metal, ceramic, and composite surfaces to improve resistance to wear-and-tear and increase longevity.
Different types of thermal sprays, such as some of the examples seen here www.poeton.co.uk/surface-treatments/thermal-metal-sprays/, suit specific industrial applications depending on the coating material, operating conditions, and required performance. There are six common options:
Flame Spray
Flame spray is one of the oldest and simplest thermal sprays, and it’s relatively affordable and easy to apply. It uses a fuel gas and oxygen flame to melt coating material before compressed air propels it onto a surface.
Plasma Spray
Plasma spray creates an extremely high-temperature plasma jet that can melt metals, ceramics, and other advanced materials. This process is commonly used in aerospace, energy, and medical manufacturing.
Cold Spray
Instead of melting the coating material, cold spray accelerates powder particles at supersonic speeds using compressed gas. This minimises heat-related damage and oxidation and produces strong, high-quality coatings for sensitive components.
Arc Spray
Arc spray uses two electrically charged metal wires to create an electric arc that melts the coating material. Compressed air then atomises and sprays the molten particles onto the substrate.
High Velocity Oxygen Fuel
HVOF spraying uses a pressurised combustion process to propel coating particles at extremely high speeds. This creates dense, highly bonded coatings for excellent wear resistance.
Detonation Spray
Detonation spray uses controlled explosions of oxygen and fuel gases to accelerate coating particles toward a surface at very high velocity. This produces an exceptionally dense, hard coating.
