Thermal spray is a surface coating process used to protect and improve metal components by heating a coating material and propelling it onto a prepared surface, where it bonds and forms a strong, durable layer. This process is widely used in manufacturing, engineering and industry because it can extend the life of parts without the company having to replace them.
What is thermal spray?
The process involves melting or heating a material – such as metal – and spraying it at high speed onto a surface. The tiny heated particles hit the component, flatten and quickly cool, building up a coating layer by layer.
Thermal sprays, like www.poeton.co.uk/surface-treatments/thermal-metal-sprays, rely on kinetic energy and heat to create this bond, forming a protective surface without affecting the entire structure of the original part.
The Heating and Spraying Process
There are different methods used to heat and project the material, including plasma, flame and electric arc systems. In each case, the coating material is either in powder or wire form.
The material is heated to a high temperature, then accelerated toward the component using compressed gas or an electric arc. When the particles strike the surface, they spread out and solidify almost instantly, gradually building up to a dense and protective coating.
Building the Coating Layer
The coating is applied in multiple passes to achieve the required thickness. Because the process adds material rather than removing it, worn or small components can be rebuilt to their original dimensions. The final surface can then be finished by grinding or machining if you need a more precise finish.