There are a variety of forms of thermal spraying that have different benefits to certain applications. Depending on the products use in its industry will determine which is the most effective and the most commonly used from of thermal spraying.

In this Alphatek blog, we explore thermal spraying, what is it used for and most importantly what is the most commonly used form of thermal spraying.

What Are The Types Of Thermal Spraying?

Thermal spray processes have been widely used in various industrial fields to enhance surface properties of various engineering parts.

A variety of metals are generally soft and are affected by external properties.

Through applying various coating materials to light metal surfaces by thermal spray processes, the wear resistance, thermal resistance, and corrosion resistance of engineering parts can be significantly improved.

Here are the 5 most commonly used forms of thermal spraying:

HVOF High Velocity Oxygen-Fuel Spraying

HVOF is a process which makes use of a torch that allows the flame to spread whenever the nozzle is used. This creates rapid acceleration which speeds up the particles in the mixture. The result is an exceptionally thin coating which is evenly applied. Despite being thin, this coating is strong and adheres well. Its resistance to corrosion is better than plasma coatings, but it is not well suited for high temperature environments.

Flame Spraying

Flame spraying is an excellent option for surfaces which aren’t designed to handle extreme stress. The coating which results from this process is not strongly attached to the surface since the spraying mechanism is powered by a lower flame velocity. The flame will be generated via oxygen which has been combined with fuel, and this will melt the mixture. Combustion flame spraying is popular for low intensity applications due to its low cost.

Plasma Spraying

Plasma spraying makes use of the plasma torch as the main tool for heating and spraying the coating. After the powder material has been melted down, it is then placed on the product in a manner which is like flame spraying. The coatings which result from plasma spraying may be a few micrometres thick to a few millimetres think. While powder is the most widely used material, metals and ceramics are also used.

This method of spraying is highly popular due to its adaptability. At Alphatek, we call it an engineering dream because of its versatility.

Fluoropolymer Coating

Fluoropolymer coating is a blend of high-performance resin and fluoropolymer lubricants. This specific coating offers many useful properties. They lend themselves and add real value to many individual applications. In short, Fluoropolymer Coatings are a design engineers’ dream, allowing greater flexibility of design from the start.

Two-Wire Electric Arc Spraying

This spraying method utilises an arc point which is created between two wires which are electrically conductive. Melting will occur at the point where the wires connect. The arc allows for heating which in turn creates deposition and melting, like flame spraying which is used with a torch. Compressed air will be used for spraying the coatings. This procedure is popular due to its cost effectiveness and will typically use aluminium or zinc as the base material.

Thermal Spraying Specialists

We wouldn’t call ourselves specialists without the evidence. Here at Alphatek, we can provide all of the 5 thermal spraying processes mentioned above. In terms of the most commonly used form on thermal spraying, in our warehouse HVOF (Tungsten Carbide) is by far our most used method of coating.

We are on of the only UK manufacturers and supplier of metal spray equipment, consumables, and wires. The company is proud to be considered as leading experts in the supply and support of advanced, innovative surface coating technology.

Working closely with our customers over the years, we have developed our products and services to deliver the best value, most effective thermal spray coatings solution, first time, every time and with a stress-free service that suits everyone.

Alphatek: Contact Us

We hope we have answered your question ‘What Is The Most Commonly Used Form Of Thermal Spraying?’. If you are looking for any other information, visit our blog page.For Metal Spraying and Thermal Spray Coating specialists, look no further than us, Alphatek. You can call us directly on 01706 821021, or you can 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.