All About Thermal Spray Coatings

When two surfaces come into contact and relative motion is generated, the contact stresses increase due to the small percentage of load-supporting area, resulting in friction, wear, and possible component failure. Surface modification and redesigning components can help address these concerns, but an effective and high-performance solution is to apply thermal spray coatings on your part’s surface.

What is a Thermal Spray Coating?—A Heat Source Applying Materials for Coatings

Thermal spray coatings are a high-technology solution to extend the lifespan of various parts. Encompassing a diverse range of surface engineering technology, thermal spray methods deposit a wide variety of materials onto a substrate to form a coating that protects or enhances the final component. Thermal sprays have been in use for over a century to improve industrial components and structures, offering wear resistance, corrosion resistance, thermal insulation, electrical conductivity, and many other effects.

Thermal Spray Coating Processes

All thermal spray methods and processes rely on the principle of heating a feed stock, then accelerating it to a high velocity before allowing the particles to strike the substrate. These particles then deform and freeze, forming a coating mechanically bonded to the substrate, but exact methods vary depending on your goals. Each variant uses a unique process to heat and accelerate the material particles—which could include metals, alloys, ceramics, and others—that form the coating. Common types of thermal spray methods include:

• High-Velocity Processes (HVOF Coatings)
• Flame Spray Coatings
• Plasma Spray Coating
• Electric Arc Spray
• And many others!

The right thermal spray process for your application will depend on your desired results and effects. Call 330-753-8458 to speak with a thermal spray coating expert to find your best solution.

What Materials Are Used In Thermal Spray Coatings?

Numerous materials can be used to create thermal spray coatings. Since finding the right coating is crucial, Hannecard - ASB Industries will work with you to determine the best coating material for your needs. We work with metals, alloys, carbides, ceramics, and more to give our customers top quality coatings that deliver the performance and protection their applications require. Some of the materials that we utilize, include:

Metals

• Aluminum & Aluminum Alloys
• Babbitt
• Carbon Steels
• Copper
• Inconel
• Nickel & Nickel Alloys
• Stainless Steels
• And More

Carbides

• Tungsten Carbide
• Chrome Carbide

What Are Applications for Thermal Spray Coatings?

Initially developed in the late nineteenth century as a metallizing process, thermal spray methods have evolved over the past century to include other materials and apply to many different substrates. Today, this technology is widely used across industries, including aerospace, automotive, energy, steel, biomedical, and many others. Common thermal spray coating applications include:

• Coating turbine blades to improve wear resistance and extend lifespans
• Applying thermal barrier coatings to gas turbine components for enhanced efficiency
• Depositing biocompatible coatings on medical implants to reduce the risk of rejection
• And many more!

How Can Thermal Spray Coatings Benefit My Application?

Thermal spray coating adds many advantages and benefits to industrial applications across markets. While the exact benefits will vary depending on your selected process, some examples include, but are not limited to:

• Diverse thermal spray methods deliver your required results
• Several applicable materials to fit your specifications
• Improved heat resistance through thermal insulation against excessive loads
• Improved workflow and operations through longer lasting components
• Improved wear resistance, corrosion protection, electrical insulation, and more

Making Sure a Thermal Spray Coating Option is Best for your Applicaiton

While thermal sprays can serve a multitude of options for many OEMs and manufacturers, sometimes inherent properties are not the best solution for all applications. Certain part shapes and sizes are suitable for thermal spray coating technologies due to achieving optimal coating angles. Many time extreme heat or high forces—which may be a possible option for welding that HRC/ASB can offer. Additionally, some requirements for thick coating which may weaken properties and impact the overall performance of components.

If thermal spray technology is not right for your application, cold spray coatings and other protective surfacing methods are available to match your requirements. Always consult with a surfacing technology expert to find your best solution.

Hannecard – ASB Industries Can Help Identify Your Best Thermal Spray Technology

Hannecard – ASB is your leading single-source provider of turnkey thermal spray technology and other surfacing solutions. Our experienced workforce will work closely with you to understand the demands of your of your requirements, planned production, and practical and common sense goals. We’ll provide personalized service with  pricing, recommending the best coating option(s) for your project.

Contact us today to learn more about thermal spray coating and our surfacing services. Request a quote to start your order.