Thermal spraying has a wide range of applications across multiple industries, but what exactly is it and how does thermal spraying compare to traditional methods in the automotive industry?

Surface Modification Processes in the Automotive Industry

Surface coating treatments have long been used in the manufacture, maintenance and repair of parts in the automotive industry, both for functional and aesthetic purposes. The traditional phosphating process, for example, was first used by Henry Ford at the start of the 20th century to protect cars from corrosion.

However, modern automotive systems demand modern surface treatments and changing demands, coupled with rising energy costs and a greater awareness of environmental issues, have highlighted the need for new, improved methods. Fortunately, technological and scientific developments have resulted in the creation of updated processes that are better equipped to meet these changing demands.

Modern methods such as thermal spraying can be used to improve the lifespan and weight-bearing capabilities of automotive parts, as well as reduce friction and corrosion.

How Does Thermal Spraying Work?

Thermal spraying is a coating process that involves materials being used in a molten or semi-molten state to coat a surface. These materials can be either metallic or non-metallic; in the case of metallic materials, this is also known and referred to as metal spray coating.

A thermal spraying system involves the spray gun, which performs the melting and accelerates particles onto the surface. A feeder supplies the powder, wire or liquid to the gun. A gas or liquid is then used to generate the flame or plasma jet to melt the material and a robot manipulates the position of either the torch or the surface to be coated.

There are several different types of thermal spraying processes, including plasma spraying, arc wire spraying, flame spraying and HVOF (High-Velocity, Oxy-Fuel Coating). Warm spraying, cold spraying and detonation spraying are also types of thermal spraying processes.

How Is Thermal Spraying Used In the Automotive Industry?

There are many applications for metal spraying in the automotive industry, including:

Interior Detail

Thermal spray coatings can be used to add interior detail to vehicles, such as precious metal surfaces or alloy detailing.

Exterior Panels

Thermally sprayed coatings and other specialist metal finishes have a range of applications when it comes to exterior automotive panels. From protecting panels from everyday wear and friction protection to specialist new composite panel technologies such as composite carbon-fibre panels with metal skins.

Turbocharger Coatings

Turbochargers are increasingly relied upon to increase the power output of vehicle engines and a turbocharger’s efficiency can be significantly improved by reducing mechanical friction. Thermal spraying can also be used to apply abradable coatings for maximum efficiency.

EGR Valve Coatings

EGR (exhaust gas recirculation) valves are a crucial component of a modern exhaust system, responsible for recirculating a portion of the exhaust gas back to the combustion chamber and reducing temperature. Thermal spray coatings improve the lifespan and efficiency of EGR valves.

What are the Benefits of Thermal Spraying Over Traditional Methods?

Thermal spraying technology has been embraced by the automotive industry because of the many benefits it provides, such as preventing corrosion and wear and tear, reducing friction, and increasing the performance and longevity of parts.

There are several advantages to thermal spray coatings in comparison to other methods. Here are just some of the benefits of using thermal spraying for surface modification.

  • Compared to traditional surface coating methods, thermal spraying offers greater thickness capability
  • There are no size or shape restrictions on the parts that it can be applied to
  • A wide selection of spray materials can be used
  • It can be applied to a broad range of substrate materials
  • Thermal spraying produces minimal noxious waste
  • The process is quick and efficient
  • It can be performed on-site
  • The coating can be formed while keeping the substrate at a relatively low temperature

Contact Alphatek

Alphatek has an extensive and well-established history providing metal spraying solutions for the Automotive Industry, and working with prestigious global brands such as Aston Martin, Bentley and Bugatti.

If you’re looking for professional thermal spray coating and metal spraying services, look no further than Alphatek. With over 100 years of cumulative coating expertise, we’re industry specialists and we believe there’s no real shortcut to what experience can teach.

We hope this blog has explained how thermal spraying compares to traditional methods in the automotive industry, but if you have further questions, please don’t hesitate to get in touch with our team of experts.

You can call 01706 821 021 or email us at postbox@alphatek.co.uk. You can also pay us a visit in person. Alphatek is located just 20 miles North of Manchester, and you can find our opening times here to help you plan your visit.