Which Thermal Spray Type Is Right For Your Project?

When it comes to protecting and enhancing the performance of surfaces, thermal spray coatings are a versatile and effective solution. However, there are various thermal spray methods on the market, so deciding which thermal spray is right for your project can be challenging. In this blog post, we’ll explore different thermal spray techniques and offer insights to help you make an informed decision on which thermal spray type is right for your specific needs.

Key Thermal Spray Types

There is an abundance of thermal spray types available, all with their own advantages and applications.

Flame Spray

– Process: In flame spray, a gas is used to melt the coating material, which is then propelled onto the substrate.

– Applications: Flame spray is used for a wide range of materials, including metals, ceramics, and polymers.

– Advantages: Arguably the most cost-effective, versatile, and applicable to large scale and delicate applications.

Arc Spray

– Process: Arc spray involves melting the coating material using an electric arc generated between two conductive wires.

– Applications: Commonly used for corrosion protection coatings on larger components.

– Advantages: Excellent strength, and minimal heat input.

Plasma Spray

– Process: Plasma spray uses a high temperature plasma arc to melt and propel the coating material onto the substrate.

– Applications: Ideal for high-performance applications, such as automotive components.

– Advantages: Plasma spray is the right thermal spray type if the project requires precise control over coating properties.

HVOF (High-Velocity Oxy-Fuel)

– Process: With HVOF, the clue is in the name. A mixture of oxygen and fuel creates a high-velocity stream of gases, which propel the coating material onto the substrate.

– Applications: Known for producing dense, wear-resistant coatings, often used in the print and paper industry.

– Advantages: HVOF coatings offer many advantages including high coating density, improved adhesion and brilliant abrasion protection.

Deciding Which Thermal Spray Type Is Right For Your Project

If you are looking at the above list of thermal spray solutions and still don’t know which thermal spray type is right for your project, consider the following things:

Consider material compatibility – Different thermal spray types are suitable for specific materials. Before choosing the right thermal spray type for your project, it’s important to consider the material’s and spray type’s compatibility to ensure optimal performance.

Evaluate project requirements – Knowing what the key performance characteristics required for your project are, whether it be wear resistance, corrosion protection, or thermal insulation is key to helping you decide the right thermal spray type for your project.

Cost considerations – The overall experience of a thermal spray coating process can cost; considering the equipment, materials and labour. With that being said, however, there are some solutions that may be more cost effective than others when it comes to meeting your requirements.

Surface preparation – Knowing the substrate’s condition and requirements for surface preparation is key to knowing which thermal spray type is right for your project. Some thermal spray methods may demand specific surface preparations for optimal performance.

Consult with experts – The list of things to consider may seem daunting. In which case, our biggest piece of advice is – leave it to the experts! Alphatek has decades of experience providing thermal spray coatings to a wide range of projects and industries.