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When Should Thermal Spray Coatings Be Used?

When should thermal spray coatings be applied? This question is often asked by those looking for a unique coating solution for a particular application. The answer varies depending on the application, but a common thread throughout is a desire to minimize corrosion and maximize product performance. This article will discuss some of the benefits and challenges associated with applying thermal spray coatings to various types of substrates. Regardless of the application, it is critical to understand the specific requirements of the material.

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Among the benefits of thermal spray coatings is their ability to protect a wide range of surfaces from hydrocarbon combustion. They save fabricators and designers the costs of heat-treatable alloys and other materials. Because a variety of materials can be fabricated and thermal-treated, thermal spraying offers a low-cost, high-performance solution for many industrial wear and corrosion problems. High-temperature galling, high-temperature corrosion, and molten zinc handling are just a few examples of the applications where thermal spraying has been successful.

Thermal spray coatings are an excellent solution for emergency part repairs, onsite service, and mis-machined components. A thermal spraying process can help identify the causes of wear and tear and correct them with a single application. By restoring a part to its pre-application condition, thermal spray coatings can minimize downtime and help a manufacturer maintain a production schedule. For information on HVOF, go to

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In the aerospace, mechanical, and electronic industries, thermal spraying is a cost-effective solution to protect critical components against wear, corrosion, fatigue, abrasion, and high temperatures. It is a great way to increase the life of new parts, and restore old parts to top form. And because thermal spraying is so versatile, it is easy to choose the right material for your application.

Plasma coatings are the newest and most efficient thermal spray process available. This process involves heating a powder material to a temperature that is just right for spraying. A plasma gun is used to generate the flame, which melts the powder and sprays the coating onto the substrate. Plasma spraying can be used on a wide variety of materials, from ceramics to metals. However, it is crucial to know the application process and its limitations before beginning the process.

One type of thermal spray coating is HVOF (high-velocity oxygen fuel). This process applies the coating material to the surface at supersonic speed, forming a strong mechanical bond with the substrate. This type of thermal spray coating is especially effective in applications that require high wear resistance and tight tolerances. However, it is important to consult with a professional before applying this coating, and consider the application process carefully.


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