The substrate to be coated and the desired effect are two of the first factors to consider when choosing a thermal coating. While certain thermal spray coating techniques, such as vacuum plasma spraying, are far more restricted, they can be applied to laminate surfaces, plastic surfaces, or metallic surfaces. 

The environment to which a thermal coating spray  will be exposed is the second most important design factor. A refractory coating can be necessary for a high-temperature application, while an anodic coating might be recommended for highly corrosive ones. To know more and to learn to choose the best material for thermal spray coating, continue reading: 

Deposition Techniques 

Layers and layers of flattened liquid drops, also known as splats or lamellae, define  thermal spray coatings. The spaces between these overlapping lamellae and their overlap dictate the coating’s thickness and porosity. The deposition method significantly impacts these surface properties.  

Arc spraying 

Arc spraying is among the most efficient and cost-effective ways to apply a thermal spray coating. Arc spraying involves melting a wire feed to create a molten pool at the gun head using a DC power source to create an electric arc. Tiny droplets of the molten substance are atomized and propelled toward the treated surface by dry compressed air. 

Up to 4 mils of semi-porous coating can be produced by arc spraying. Of all thermal coating methods, it has the highest deposition rate.   

Additionally, it uses less power, works better for metalizing thermally sensitive substrates, and produces stronger bonds than flame spraying. 

Flame spraying 

Another affordable thermal spray coating india is flame spraying. Flame spraying involves using a fuel source, and the heat of combustion melts either a wire feed or a consumable powder to create a molten pool. Compressed air atomizes and drives molten material like arc spraying toward the work area. 

Flame spraying is a practical way to apply a thermal spray coating, and its moderate spray rates distinguish it. Compared to arc spraying, it creates less dust and fumes. 

It is preferred when painting huge or intricate structures because it provides more material alternatives than arc spraying, such as ceramics and other non-metallic coatings. 

Plasma spraying 

Plasma thermal spray coating services use a high-temperature plasma flame. They heat and accelerate a powdered consumable toward the work area. An inert gas and a DC electric arc interact, and the resistive heating from the electrical arc causes the gas to ionize and dissociate, creating a plasma jet. 

Materials with unusually high melting points are used in plasma spraying to provide a very high-quality coating. It is possible to perform the procedure in a vacuum chamber, or VPS, to enhance the coating surface quality. 

Various substrates and coating materials can be used with plasma spray because of its versatility. 

High-velocity Oxygen Fuel (HVOF) 

High-velocity Oxygen Fuel (HVOF) heats and accelerates powdered materials using an expanded nozzle and confined combustion. It can operate at hypersonic gas velocities and create a dense, well-adhered coating resistant to wear, corrosion, and hardening. 

Due to the multiple process variables impacting coating consistency, HVOF is rarely performed manually. 

Final thoughts 

Remember the coating procedure of thermal spraying affects the quality of the coating. So, contact EWS Endurance Wear Solutions for thermal spray coating services. You can get the best surface modification services from EWS Endurance Wear Solutions.