Thermal spray coating processes have become an integral solution in enhancing various materials’ performance, durability, and efficiency across different sectors. These techniques involve applying a protective layer to a surface or material using heat. Thermal spray coating solutions can host an array of benefits including improved resistance to wear, corrosion, and other factors. In this blog, we will delve into 5 types of thermal spray coating processes that play a crucial role in a variety of applications.
5 Types Of Thermal Spray Coating Processes
There are a multitude of processes that all host different benefits for different applications and industries. Let’s explore the top 5.
1. Flame Spraying:
Flame spraying is arguably one of the simplest thermal spray coating techniques and the most traditional. This process is where melted materials, usually wire or powder, are sprayed onto a surface with the help of a high-temperature flame. The molten material is propelled onto the substrate, creating a protective coating as it solidifies. Flame spraying offers many benefits to a variety of industries thanks to its versatility.
2. Arc Spraying:
Arc spraying is a process that involves an electric arc in order to melt the coating material, typically in the form of wire. Similar to flame spraying, the result of the process is a protective coating, however, this process uses a wire arc to get optimal results. Arc spraying is known for its ability to quickly produce thick coatings, which is what makes it a sought after thermal spray coating process for applications that require corrosion resistance.
3. Plasma Spraying:
A popular thermal spray coating process is plasma spraying. Plasma spraying involves the use of a high-temperature plasma jet to melt the coating material, which is typically in powder form. Plasma spraying is well known for its precision, making it ideal for applications in aerospace, electronics, and even the medical sector. This technique enables applications to use a variety of materials, including ceramics and metals.
4. High-Velocity Oxy-Fuel (HVOF) Spraying:
Possibly one of the most popular processes here at Alphatek. HVOF spraying is a thermal spray coating process that is widely used across a variety of industries and applications. HVOF spraying is a thermal spray process that is best suited for those surfaces that need wear resistance, high or low friction, and abrasion protection, often applied to roll surfaces used in paper production. The high velocity of this process results in coatings with dense structures, which offer excellent wear and corrosion resistance. HVOF coatings are commonly used in applications where high-quality and high-performance coatings are essential.
5. Detonation Gun Spraying:
Not as scary as it sounds. Detonation gun spraying or sometimes just known as detonation spraying is a specialised thermal spray coating process that involves the a mixture of fuel and oxygen to produce a high-velocity spray of coating material, intended to change surface characteristics. This process is particularly effective for depositing hard and wear-resistant coatings where durability is the main aim. The high kinetic energy of the sprayed particles contributes to the high resistance of these coatings.
Thermal Spray Coating Processes At Alphatek
Thermal spray coating processes have revolutionised the way we protect and enhance the performance of various materials, in various industries.
Whether it is disability or corrosion resistance that you require, there is a process that fits the needs of any application, From the simplicity of flame spraying to the precision of plasma spraying, each technique offers unique advantages suited to specific sectors.
It is no surprise that companies of all sizes, and all origins trust us with their thermal spray coating projects, thanks to our wide range of coating processes on offer here at Alphatek.
If you would like to know more about our thermal spray coating processes or if you are unsure as to which process is right for you, get in touch with our team today!
You can reach us by calling 01706 821021 or emailing postbox@alphatek.co.uk.
