Thermal spray coating refers to a number of processes in which a substrate is coated to improve functional performance. Many types of coating materials can be applied by thermal spray processes. Coatings can range in thickness from a thousandth of an inch up to an eighth of an inch. Thermal spray coatings have been used to protect parts from wear, abrasion, corrosion, high temperatures, etc. and to build dimensions on undersized parts.

Thermal spray coating processes involve the deposition of coatings from a stream of high velocity finely divided particles in a molten or semi-molten state impinging onto the substrate. These processes use fine powdered source material or sometimes metal wire that is molten and broken into fine droplets. The coating gun adds thermal energy to bring the materials to a plastic or molten condition and accelerates these materials at high velocities toward the substrate.

There are several different types of Thermal Spray Coating processes. They differ in how they apply thermal and kinetic energy to the source material, the form of the source material (powder or wire) and the relative velocities and temperatures of the flame. Each process has advantages and disadvantages, and some are optimized for certain types of coatings.

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