Thermal spray introduction

Thermal spraying, also commonly known as metal spraying is a surface engineering / coating process where a wide range of metals and ceramics can be sprayed onto the surface of another material. Thermal spraying is widely used to provide corrosion protection to ferrous metals or to change the surface properties of the sprayed items, such as improve the wear resistance or thermal conductivity. The range of thermal spray applications is vast and a selection of them are summarised in our applications section link to applications. Other examples are shown on our Blog link and Press releases link. If you can’t find your application or want to learn more, please contact us or one of our resellers who will be pleased to help.

The process basics

All methods of thermal spraying involve the projection of small molten or softened particles onto a prepared surface where they adhere and form a continuous coating. To create the molten particles, a heat source, a spray material and an atomisation/projection method are required. Upon contact, the particles flatten onto the surface, freeze and mechanically bond, firstly onto the roughened substrate and then onto each other as the coating thickness is increased.

The metal spray equipment falls into four main categories, Flame Spray, Arc Spray, Plasma Spray and High Velocity Oxygen Fuel (HVOF). More detailed information on each process can be viewed by clicking on the process tabs.

Materials, accessories and automation

An important part of the thermal spraying process are the spray materials and Metallisation can supply a wide range of quality thermal spray wires and (powders)[http://www.metallisation.com/powders.html.]

To assist the thermal spraying process, we also offer a wide selection of accessories, from nozzle cleaners to masking products, DFT thickness gauges and deflected spray extensions to name just a few.

Metallisation also supply automation systems to automate production processes. These include LPG bottle spraying systems , aluminium multivoid tube spraying systems, (ERW tube mills)[http://www.metallisation.com/videos/library/erw-tube-mill-weld-seam-repair.html], (pipe spraying systems)[http://www.metallisation.com/videos/library/auto-pipe-spraying.html] , dust extraction, robotic installations and general thermal spray acoustic booths / turntables / manipulators.

The process basics

All methods of thermal spraying involve the projection of small molten particles onto a prepared surface where they adhere and form a continuous coating. To create the molten particles, a heat source, a spray material and an atomisation/projection method are required. Upon contact, the particles flatten onto the surface, freeze and mechanically bond, firstly onto the roughened substrate and then onto each other as the coating thickness is increased.

The metal spray equipment falls into four main categories, Flame Spray, Arc Spray, Plasma Spray and High Velocity Oxygen Fuel (HVOF).

Equipment, materials and applications

For more information on the four processes and the equipment used to perform thermal spray, please visit our Products section for our complete range of thermal spray equipment and materials.

We also have an applications section showing a range of the most common applications for thermal spray. Why not have a look here to see if someone is already coating products similar to yours.