An Overview of Thermal Spraying

Thermal spraying is a surface strengthening technology and an important part of surface engineering technology.

Thermal Spraying Definition

Thermal spraying is a metal surface processing method in which a sprayed material in a molten state is atomized and sprayed on a surface of a part by a high-speed air flow to form a sprayed layer. We call the special work surface “coating” and the working method of making the coating “thermal spray”. It is a general term for spraying and spray welding with various heat sources.

Thermal Spraying

Thermal Spraying Principle

Thermal spraying refers to a series of processes in which finely dispersed metal or non-metallic coating materials are deposited in a molten or semi-molten state onto a surface of a prepared substrate to form a sedimentary layer .

The coating material may be in the form of powder, ribbon, filament or rod. The thermal spray gun provides the necessary heat from the fuel gas, arc or plasma arc, heats the thermal spray material to a plastic or molten state, and is then subjected to the acceleration of the compressed air, causing the constrained particle beam to impinge on the surface of the substrate. The particles impinging on the surface are deformed by stamping to form a laminated sheet which adheres to the surface of the prepared substrate, and then cools and accumulates, eventually forming a layered coating.

Thermal Spraying Processes

1) Heating a powdery or filamentous metal or non-metal material to a molten or semi-molten state by using a heat source such as an electric arc, plasma spraying or a combustion flame;

2) Spraying the material to the surface of the pretreated substrate at a certain speed by means of compressed air;

3) The material is deposited on the surface of the substrate to form a film.

theraml spraying process

Thermal Spraying Applications

Thermal spraying technology can achieve coatings of different hardness, wear resistance, corrosion resistance, heat resistance, oxidation resistance, heat insulation, insulation, electrical conductivity, sealing, disinfection, anti-microwave radiation and other special physical and chemical properties. It can be used in equipment repairs, re-use of scrapped parts, and can be strengthened and pre-protected in new product manufacturing to extend its service life.

Thermal Spraying Material

Spraying powder plays an important role in the entire thermal spray material. Thermal spray alloy powders include nickel-based, iron-based and cobalt-based alloy powders, which are applied to the repair and protection of mechanical parts according to different coating hardness.

Stanford Advanced Materials supplies high-quality coating materials to meet our customers’ R&D and production needs. Please visit for more information.

One Reply to “An Overview of Thermal Spraying”

  1. Very Unique concept for me actually, never heard of this term thermal spray. Actually, I completely belong to another field, so I actually don’t have any idea about this concept of Thermal Spray. But, I now quite to get a little bit about this process of thermal spraying, thanks to you that you shared this blog with us. Really informative content and very nice. Thank you for sharing this great blog.

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