Metal spraying, also referred to as thermal spraying, involves applying a metallic coating to a variety of surfaces via a molten particle spray.

Turbocharges, exterior panels, and EGR valves are just a few of the parts on modern automobiles that have thermal spray coatings applied to them. Vintage cars, for instance, are frequently refurbished by utilising metal sprays to restore and preserve body panels in contrast to new, mass-produced automobiles.

The benefits of thermal coatings in the automobile industry as well as their usage will be covered in this Alphatek article.

Usage of Thermal Spray in Automotive Industries

Although thermal spray coatings have a wide range of uses in the automobile sector, they are most frequently employed on turbochargers, external panels, EGR valves, and several other internal vehicle components.

Thermal spray technology comes in a variety of forms and can be applied for a variety of purposes.

Combustion Spray

The process of projecting molten material onto the surface to generate the coating is also known as low-velocity oxygen and fuel spraying. Repairs, efficiency improvements, and restoration of the surface or components’ shapes and dimensions are often accomplished via combustion spraying.

Plasma Spraying

The most diverse coating in our selection is plasma spraying.

A molten, highly accelerated coating of particles is sprayed onto the surface by an extremely effective and energetic plasma jet. It is typically used for defence against wear and tear, resistance to corrosion, and oxidation resistance.

Arc-Wire Spraying

This method of thermal spraying requires making an arc out of two electrically charged metallic wires. The coating itself is normally denser than a flame-sprayed version due to the strong bond that is created. A bond created because of the specific spraying technique between the coating and the surface.

With the appropriate thermal spray technology, it is perfectly possible to safeguard and extend the life of your car as well as its components.

What Are the Benefits of Metal Spraying on Vehicles?

There’s a wide range of benefits to metal spraying in many industries, especially the automotive industry.

Wide Variety of Coating Materials

The metal spraying process can produce high quality coatings from a wide variety of various materials. These can take the shape of; powder; rod; ceramic; plastic; polymer; wire; metal, and alloy.

Since the coating method can be specially chosen for each unique substrate and it’s performance task, a close match between the two is frequently possible.

Almost every material can be coated using the thermal spray technique so long that the substrate itself can withstand the intense temperatures from the thermal spray process.

The spectrum of substrate materials is further expanded by a number of particular spray coating techniques. Those which operate at significantly lower temperatures, in fact, to match the substrate’s needs.

Increase Component Life Expectancy

Any strong barrier that acts against surface erosion, decomposition, and other degradation will help to prolong the lifespan of car and engine components. Therefore, a strong and efficient metal spray coating will do exactly that.

Compared to conventional coating processes, thermal spraying enables the application of much thicker coatings (sometimes up to 10mm) at great deposition rates. Something that creates a barrier that is much more effective against issues like wear and tear.

Financial Reductions

In many circumstances, adding a metal spray coating to an item to repair it is significantly less expensive than replacing it altogether.

Additionally, metal spray coatings have a tendency to be considerably more effective and waste less substance than other methods, making them a much more sensible choice when using coating ingredients that are more expensive.

Here’s some other benefits of using thermal spray coatings in the automotive industry:

  • Enhances the effectiveness and performance of vehicles and engines
  • Boosts motor performance and service duration
  • Decreases friction, slippage, and wear
  • Reduces heat exchange
  • Provides protection from oxidation and corrosion
  • Reduces the need for consumption of oil and fuel
  • Cuts down on carbon emissions
  • Increases fatigue resistance

Alphatek’s Thermal Spray Solutions in Automotive Industries

For applications in the automotive industry, Alphatek has a lengthy and prosperous history of offering metal spraying solutions.

Some of our most prominent automakers in the world, such as Bentley, Bugatti, and Aston Martin have benefitted from our solutions.

We use thermal spraying for the upcoming applications:

  • Turbocharger

It is unquestionable that the use of abrasion-resistant coatings can significantly increase the turbocharger’s efficiency. All whilst still ensuring optimal performance.

  • Exterior Panels

Thermally sprayed coatings, which have several uses in external car panel designs, are a specialty metal finishing technique.

  • EGR Valves

Metal spray coatings can extend the lifespan and performance of EGR valves while shortening the average duration between failures.

Check out some of our case studies to see the various automotive-specific projects we have worked on throughout the years.

Reach Out

Businesses cannot afford to lose infrastructure and equipment to avoidable damage which might have been repaired.

Alphatek has developed services and solutions in order to consistently provide the finest value in anti-corrosion coatings solutions that also come with a satisfactory for all stress-free service.

Look simply to Alphatek for your Metal Spraying and Thermal Spray Coatings in the automotive industry. Reach us through phone or email – call us on 01706 821 021 or email us at postbox@alphatek.co.uk.

If you would prefer to see us in person then do! We’re located just 20 miles north of Manchester, but make sure to make a record of our opening times.