Thermal spray coatings are widely used to protect and enhance component surfaces without significantly affecting the base material. Here are five types of thermal spray coatings.
Plasma spray coatings
Plasma spray coatings use electrically generated plasma to achieve extremely high temperatures. In a thermal plasma spray process, a wide range of materials can be applied, including ceramics and refractory compounds, producing dense coatings for high temperature or insulating applications.
High velocity oxygen fuel coatings
High velocity oxygen fuel, often abbreviated to HVOF, uses a combustion process to accelerate coating particles at very high speeds. This results in dense coatings with low porosity and strong bond strength, making them wear and corrosion resistant.
Twin wire arc coatings
Twin wire arc spraying involves creating an electric arc between two consumable wires. The molten material is atomised and propelled onto the substrate, forming coatings commonly used for corrosion protection and dimensional restoration on large components.
Combustion flame spray coatings
Combustion flame spray uses an oxy fuel flame to melt wire or powder feedstock. While coatings produced are typically less dense than plasma or HVOF alternatives, the process, like that seen here https://www.poeton.co.uk/surface-treatments/thermal-metal-sprays, is valued for its simplicity and cost effectiveness.
Cold spray coatings
Cold spray differs by using high velocity gas rather than heat to deposit particles. Materials bond through plastic deformation on impact, making this method suitable where heat sensitive substrates are required.
These thermal spray coating types offer different performance characteristics, allowing engineers to select the most appropriate solution based on operating conditions, material compatibility, and surface protection requirements.
