Thermal spraying commercial metal extends the life of parts used in extreme or harsh conditions. Using this coating technique creates a stronger surface bond that allows the part to hold up against scratches, chips, wear, abrasion and excessive heat.
The question then becomes, which of the thermal spray coating options is the best choice for your metal part and how it will be used.
How to Decide the Best Coating Option
To decide the best coating option for your metal, consider the industry, the equipment that requires the part, and the conditions the part will be exposed to.
1. High-Velocity Oxygen Fuel (HVOF) Thermal Spray
The HVOF coating provides high-density, extremely wear-resistant coating to commercial parts in oil & gas, aerospace, sewage treatment, chemical plants, and more industries.
The main benefits are increasing the density, thickness, and hardness of the metal, while also providing exceptional corrosion-resistance in extreme environments.
2. High-Velocity Air Fuel (HVAF) Thermal Spray
The HVAF coating is valuable for oil & gas industry parts. Specifically, this type of protective coating is commonly used to repair parts used in equipment for oil drilling.
The main benefits are creating heating efficiency, preventing the oxidation of metals, and preventing the decomposition of carbides in the metal.
3. Warm Spraying
Warm spraying is a newer technique that adds nitrogen to the HVOF process to create a higher coating efficiency. This is useful for parts such as metallic glass that typically deteriorate at high temperatures.
The main benefits are preventing oxidation of the metal to maintain the integrity of the metal over a prolonged period. This is critical for equipment such as pipes and tanks, transportation such as cargo ships and boats, and structures such as bridges.
4. Cold Spraying
Cold spraying consists of mixing nitrogen and helium to create a very low-temperature gas stream that is propelled onto the metal.
The main benefits are protecting the metal from corrosion and improving or restoring the composition of the metal. This is useful for parts that are used in equipment for critical industries such as aerospace, military, oil & gas, and healthcare.
5. Flame Spraying
Flame spraying is ideal for jobs where quality is not as important as cost-effectiveness. The technique uses heat to melt the surface coating and then propel the melted coating onto the metal.
The main benefits are covering a large area of metal or an entire piece of metal. This is especially useful if the metal will be fused to another piece of metal as a solution to address a design limitation during the manufacturing process.
6. Plasma Spraying
Plasma spraying is a very expensive, yet highly functional technique to coat metals with very high melting points, such as refractory metals (up to 2,000 degrees Celsius) and ceramics (up to 1,600 degrees Celsius).
The main benefits are enhancing the corrosive-resistance of parts used in equipment that requires extreme heat resistance, such as a manufacturing, chemical, power, or nuclear plants.
7. Wire Arc Spraying
Wire arc spraying is ideal for large jobs that require a higher volume of output. The coating process repeatedly propels tiny droplets of molten material onto the metal, creating a series of splats that spread out to cover the desired area.
The main benefits are restoring the composition of worn-down parts and slowing down the rate of erosion to extend the life of the metal. This is important for industries such as aerospace where engine parts are routinely exposed to extreme conditions.
Consider Our Thermal Coating Services
Our thermal spray coatings create a high-density, extremely wear-resistant coating to commercial parts without causing defects, stresses, or warping.
Contact our team today to inquire about utilizing our thermal spray coatings for your next project.