A thermal spray coating is applied across multiple applications and processes. Dependent on the use and effect needed, the thermal spray coating chosen to apply to the substrate will vary.
In terms of applying the spray coating, the process consists of a heat source (flame or other) and a coating material in a powder or wire form which is literally melted into tiny droplets and sprayed onto surfaces at high velocity.
In this Alphatek blog, we are going to explore how a thermal spray coating is applied, which applications and industries it is used, and most importantly the benefits that come from applying the thermal spray.
What Is Thermal Spraying?
Thermal spraying is a generic category of coating processes that apply a consumable as a spray of finely divided molten or semi-molten droplets to produce a coating. At the substrate surface, the particles form splats that interlock and build up to give the coating.
What Are The Benefits Of Thermal Spraying?
- Comprehensive choice of coating materials. They include; metals, alloys, ceramics, cermet, carbides, polymers and plastics.
- Thick coatings can be applied at high deposition rates.
- Thermal spray coatings are mechanically bonded to the substrate – can often spray coating materials that are metallurgically incompatible with the substrate.
- Can spray coating materials with a higher melting point than the substrate.
- Most parts can be sprayed with little or no preheat or post heat treatment, and component distortion is minimal.
- Parts can be rebuilt quickly and at a low cost. Usually at a fraction of the price of a replacement.
- By using premium material for the thermal spray coating, the lifetime of new components can be extended.
- Thermal spray coatings may be applied both manually and mechanised.
What Is The Most Commonly Used Form Of Thermal Spraying?
Thermal spray coatings are used in a wide spectrum of many useful applications, which can include protecting buildings, automotive, railways and other structures from extreme environments.
Here are the most used thermal spray coatings:
- HVOF Spraying – High-Velocity Oxygen Fuel spraying is a process to apply very dense, strongly adhered coatings.
- Plasma Spray – Plasma coating is the most versatile. It’s designed to treat industrial parts that are exposed to many different elements such as heat or wear and tear.
- Arc-Wire Spraying – This coating involves two consumable metal wires. When fed into a spray gun the wires are heated to melting point and sprayed onto a metallic surface.
- Flame Spray – Flame spraying is a cost-effective alternative for applying metallic and ceramic coatings in a low-velocity environment and for those delicate applications.
- Fluoropolymer Coating – In short, Fluoropolymer Coatings are a design engineers’ dream, allowing greater flexibility from the start.
Thermal Spray Coatings Applications And Industries
A range of components benefits from thermal spraying, either as part of the original manufacturing process or as a restoration or re-engineering technique.
Some materials are used for smaller applications, and others are sprayed in huge quantities. Each application uses a thermal spray coating and material to yield the desired benefits and effect.
A few common industries include:
- Oil & Gas
- Rail
- Paper & Print
- Automotive
- Aerospace
- Defence
- Utilities & Clean Energy
Alongside our range of thermal spray coatings, we have also developed numerous industry-specific coating solutions. They are tailored to meet the exact requirements of our client’s individual needs.
Alphatek: Get In Touch
Here at Alphatek, we have a combined over 100 years of cumulative coating expertise in house. We have seen a lot and believe there’s no real shortcut to experience.
Working closely with our customers over the years, we have developed our products and services to deliver the best value. The most effective thermal spray coatings solution, first time, every time and with a stress-free service that suits everyone.
For Metal Spraying and Thermal Spray Coating specialists, look no further than us, Alphatek. You can call us directly on 01706 821021 or email us at postbox@alphatek.co.uk.
Alternatively, if you’d like to visit us, we are located 20 miles north of Manchester. Just be wary of our opening times.
