Thermal Spray


Thermal spray, sometimes called metallizing, is a process of melting a powder or wire in a gas stream and applying the semi-molten material to a substrate. The materials that can be sprayed through thermal spray are almost endless. Ceramics, metals, carbides, alloys and even Teflon materials can be applied in this manner.

The benefits of the thermal spray process are the application to almost any substrate. The low temperature of application makes it possible for use on finished parts without causing distortion or changing the properties of the base material. Thermal spray saves you time and money by rebuilding your parts with better materials, less down time and fewer maintenance hours through the life of that part. Below are the standard thermal spray processes. For more in depth information feel free to call us at any time.




HVOF thermal spray is short for High Velocity Oxy-Fuel system. This system has been one of the major thermal spray systems in use for many years. It offers hard materials such as carbides but can also spray many different metal-based materials

Typical HVOF Thermal Spray Uses:

  • Anti-fretting

  • High-wear parts

  • Corrosion resistance

  • Anti-Galling

  • Dimensional restoration

Typical HVOF Thermal Spray Materials:

  • Tungsten Carbide

  • Chrome Carbide

  • Stellite®

  • Stainless steel




HVAF thermal spray is short for High Velocity Air Fueled system. This thermal spray system offers higher densities and bond strength than HVOF on some materials. It also allows for thicker thermal spray buildups than HVOF without the cracking issues due to its lower spray temperatures and higher velocity. HVAF thermal spray also offers the ability to spray in smaller ID areas than HVOF.

Typical HVAF Thermal Spray Uses:

  • Anti-fretting

  • High-wear parts

  • Corrosion resistance

  • Anti-Galling

Typical HVAF Thermal Spray Materials:

  • Tungsten Carbide

  • Chrome Carbide

  • Hastelloy

  • Inconel




Plasma thermal spray systems were the original systems used to produce carbide coatings and have high enough process temperatures to spray ceramics also. This thermal spray system offers lower bond strength and higher porosity than HVOF or HVAF but offers ID capabilities.

Typical Plasma Thermal Spray Uses:

  • High-temperature coatings

  • High-wear parts

  • Corrosion resistance

  • Dielectric

  • Thermal barrier

Typical Plasma Thermal Spray Materials:

  • Chrome Oxide Ceramic

  • Aluminum Oxide Ceramic

  • T800

  • Chrome Carbide

  • Aluminum polyester abradables

  • Thermal barrier coatings


Spray & Fuse


Spray and fuse is a thermal spray method that bridges the gap between standard welding and thermal spray. It has a metallurgical bond like welding but also has thinner layers of pure metal on the base substrate like other thermal spray forms. Unlike conventional thermal spray, the high heat can cause the substrate to warp or its properties to change due to the heating of the base to get the coating to fuse to it.

Typical Spray & Fuse Uses:

  • Extreme wear resistance

  • Valve balls

  • Augers

  • Exhaust fans

  • Sucker pumps

  • Pump pistons

Typical Spray & Fuse Materials:

  • Colmonoy 88

  • Nickel Cobalt

  • Tungsten Carbide

  • Nickel Chrome Alloys


Arc Spray


Arc thermal spray operates by taking two wire spools and using electricity to melt the wire and air to spray it onto the part being coated. This thermal spray system can lay down large amounts of material quickly and achieves good bond strength and hardness during the process. The interesting thing with this thermal spray process is, you can use two different wires and create a new alloy of material to tailor the coating to your needs. Arc thermal spray can also be used to build up parts that are worn greater than ¼” or more.

Typical Arc Thermal Spray Uses:

  • Shafts

  • Electrical conductivity

  • Feed rolls

  • No slip coatings

Typical Arc Thermal Spray Materials:

  • Stainless steel

  • Bronze

  • Aluminum

  • Zinc

  • Brass


Flame Spray


Flame thermal spray is one of the oldest forms of thermal spray. Typically using oxygen and acetylene, these thermal spray systems melt a wire or a powder in the combustion stream and apply it to the part. These coatings are great for restoration of old parts. The flame thermal spray system can spray I.D. and O.D. components and can be readily brought to a customers site for repairs if needed.

Typical Flame Thermal Spray Uses:

  • Shafts

  • Bearing housings

  • Casting repairs

  • Mold dyes

Typical Flame Thermal Spray Materials:

  • Stainless steel

  • Bronze

  • Babbitt

  • Nickel aluminum