Thermal Spraying Of Coatings

About Thermally Sprayed Coatings

Thermal Spray Coatings are coating methods in which melted or partially melted materials are projected onto a substrate. The coating materials, available as powders, wires or rods, are heated by electric processes (plasma or arc) or combustion flames. They are converted into micrometre-sized particles and then accelerated towards the substrate, where they form a coating.

Thermal spraying is used in several coating processes, including plasma spraying, HVOF spraying, arc spraying and flame spraying. These processes are also known as metallising spraying.

The coating quality is measured by quantifiable criteria such as porosity, oxygen content, macrohardness and microhardness, adhesion strength and surface roughness. Increased particle velocity reduces porosity, thereby improving the coating quality.

Applications of Thermal Spray Coatings

- Corrosion protection / galvanic protection
- Restoration of dimensions
- Electrical insulation
- EMI/RFI shielding
- Emissivity control
- Erosion resistance
- Resistance to lime deposits
- Prevention of bio-fouling
- Decorative or cosmetic marking
- Replacement of hard chrome plating
- Low friction detachment
- Chemical removability
- Optical or reflective properties
- Electrical or thermal conductivity
- Wear and abrasion resistance
- Solderability
- Grip and slip resistance

Key Features of Thermal Spray Coatings

Versatility: Thermally sprayed coatings can be applied to metals, ceramics, polymers and composite materials, thereby meeting diverse industrial requirements.

Diverse Coating Materials: Coatings can be produced using metals, ceramics, polymers or alloys, offering tailored solutions for specific technical applications.

Improved Wear Resistance: Thermal spray coatings increase surface wear resistance, thereby extending component lifespan and reducing maintenance needs.

Corrosion Protection: The coatings form an impermeable barrier against corrosive environments, thereby protecting substrates from degradation and chemical attack.

Thermal Barrier: Certain coatings provide thermal insulation, thereby protecting components from extreme temperatures and thermal shocks.

Thermal Spray Coatings Video