Six Metal Spray Coating Processes

Metal spray technology is a cornerstone of surface engineering, offering robust protection against corrosion, wear, and heat damage. As industries push material performance boundaries, thermal spray coating processes are becoming more advanced and essential. These coatings improve the lifespan, strength, and reliability of critical components across energy, aerospace, and manufacturing sectors.

1. Flame Spray Coating

Flame spray coating involves heating metallic or ceramic materials with an oxy-fuel flame and spraying molten particles onto the surface. It’s one of the oldest thermal spray coating methods, ideal for restoring worn parts and applying corrosion-resistant layers.

2. Arc Spray Coating

Arc spray coating uses an electric arc to melt wire materials, propelling them onto a surface with compressed air. This thermal spray coating method is cost-effective, fast, and often applied for marine or oil and gas protection.

3. Plasma Spray Coating

A plasma spray system uses ionised gas to melt powder particles at extremely high temperatures. The result is a dense, well-bonded coating suitable for aerospace turbines, biomedical implants, and engine parts. According to Grand View Research the global thermal spray market is projected to grow by over 6% annually through 2030.

4-6. Advanced Coating Methods

High Velocity Oxy-Fuel coatings deliver exceptional hardness and adhesion, while Cold Spray methods preserve material integrity by avoiding melting. Detonation Gun Spray uses controlled explosions to create extremely tough coatings.

Firms such as https://www.poeton.co.uk/surface-treatments/thermal-metal-sprays/. provide expert thermal spray coating solutions that meet stringent industrial performance demands.

By combining these six processes, industries achieve enhanced durability, lower maintenance costs, and longer equipment lifespans across global applications.