Thermal Spray is a coating process that provides a functional surface to protect or improve the performance of an affordable substrate or component. Almost any kind and form of material can be thermally sprayed - which is why thermal spray has been used world wide to provide corrosion protection, protect from wear and abrasion, restore and repair components, and more!
There are many types of thermal spray processes, but all involve the deposition of finely divided metallic or nonmetallic materials in a molten or semi-molten condition on a substrate. The feedstock material is fed into a gun, which heats the materials to a plastic or molten state and then accelerates it by a compressed gas to a substrate. The particles strike the surface, flatten, and form thin platelets or splats that conform and adhere to the irregularities of the prepared surface and to each other. As the sprayed molten particles impinge upon the substrate, they cool and build up splat by splat into a lamellar structure, thus forming a coating or spray deposit.
The basic process variations of thermal spraying are the spray feed materials, the method of heating, and the method of propelling the materials to the substrate. The feed materials used are in the form of powder, wire, rod, or cord.