Are you ready for a short history lesson? Today we’re talking about the history of thermal spraying, where it originated and what spray coatings are used for. We’ll also touch on innovations in the industry and what to expect in the future.
What Are Thermal Spray Coatings?
Thermal spray coating is a process where heat is used to turn metallic or non-metallic material into a molten or semi molten state. This is then sprayed onto another surface (the surface really varies as metal spray coatings are used across a wide range of industries!)
When the molten material is sprayed onto a surface, the particles flatten and cool down, creating a solid bond. Additional coats can be applied until the desired coating thickness is achieved.
The part that has received this treatment is then ready to use or will have further treatments or different coatings applied.
What Are They Used For?
Thermal spray coatings are used in a huge range of parts, and components, and across different industries too. From aerospace to frying pans, spray coatings really are everywhere. Because metal spray coatings are usually used to enhance the performance of a part or protect it, components used in larger machinery are frequently coated.
You can usually find spray coatings wherever there are components are parts that are under a lot of stress and will receive a lot of wear and tear. Stress can come from temperature extremes (either hot or cold), the environment, corrosion, or general use.
That’s why thermal spraying is frequently used in the manufacture of car parts – cars, both the body and all engine parts need to be tough and withstand a lot of stress from repetitive use.
Who Invented Thermal Spraying?
You may think thermal spray coatings sound pretty modern (the process behind why and how they work is pretty technical after all), but would you believe the concept is over 100 years old?
It is believed that a Swiss inventor, Max Ulrich Schoop, is the inventor, or father of thermal spray coatings because he submitted the first patents for metallic coatings in 1909.
The story goes that he got the idea from watching his sons fire toy guns that had lead bullets – observing how when fired at a surface, the lead shot left ‘splatters’. Interesting story if it’s true!
Schoop patented the use of a combustion process to melt wire and propel it onto a surface, this first patent used oxygen as fuel, and his second patent included an electric arc as a heat source – this can be used as an alternative to oxygen. These methods have been refined but are still the basic principle of thermal spraying even today.
Further Developments In The History Of Thermal Spraying
Since the invention of wire arc spraying, many variants of thermal spraying have been developed to meet a wide range of challenges.
The beauty of this is that there is now a type of thermal spray to meet a wide range of challenges, and if there isn’t one…companies like ours will try and find a solution!
From HVOF thermal spray techniques to plasma spraying, there are many ways to spray these days. Materials that can be sprayed and objects that can be coated have also increased.
This includes being able to spray substrates that aren’t metal, we’ve come up with many propriety solutions for spraying onto surfaces other than metal which includes ceramics, plastics, composite materials, and carbon fibre.
Alphatek Metal Spray Coatings
We hope you enjoyed this short history lesson on metal spray coatings!
If you have any questions about what we do or would like to come and visit our factory, please contact us.
Alphatek has over 30 years of unparalleled experience in thermal spray coatings. Quality is always high on our agenda which is why we have ISO-approved quality processes and always strive to do better.
We aren’t a small business, but we aren’t too large to care enough either – we’re proud of the friendly service we offer our clients, which includes some of the most recognisable brands in the world!
