6 Advantages of Thermal Spray Coating for Weld Cladding

Thermal spray coating is a process in which a material is applied to a surface using heat and velocity. This process can be used to apply a variety of materials, including metals, ceramics, and plastics. Of course, there are many ways to protect surfaces, but thermal spraying creates a smooth and uniform deposit with very little risk to the substrate.

That being said, let's delve into a few advantages of using thermal spray coating:

1. Thermal Spray Coating Can Be Used to Apply a Wide Range of Materials

One of the great things about thermal spray coating is that it can be used to apply a wide range of materials from soft thermoplastics and conventional metals like steel and bronze to hard coatings like tungsten carbide and ceramics. This means that you can choose the best material for your particular application, whether it's for dimensional restoration, clearance control, surface conductivity, wear resistance, corrosion resistance, or heat resistance..

2. Thermal Spray Coatings Can Be Applied Very Thinly

Another advantage of thermal spray coating is that it can be applied as little as 0.003” thick. This is important when a larger dimensional change would adversely affect performance. With thermal spray coating, you can apply a very thin layer of material, which will provide the desired protection without affecting the function of the part.

3. Thermal Spray Coatings Are Very Durable

When properly engineered and used as designed, thermal spray coatings can withstand substantial wear and remain effective for years. Coatings for both wear and corrosion applications can extend surface life by many multiples. In one well documented study, corrosion protection by thermal spraying lasted more than 19 years, well beyond the planned life of the study. 

4. Thermal Spray Coatings Are Resistant to High Temperatures

High temperature can significantly reduce the wear resistance of even high-performance alloys. Some thermal spray coating materials are specifically designed to perform at high temperatures to protect critical surfaces in hot environments like power generation boilers and turbine engines.

5. Thermal Spray Coating Is Relatively Inexpensive

Since even thin thermal spray coatings can offer substantial protection, the cost of adding a protective coating is frequently much more favorable than engineering a thicker, heavier part or switching to a more costly, higher-performing alloy. Thermal spray coatings offer savings in both fabrication cost and weight.

6. Thermal Spray Coating Can Be Applied to Complex Shapes and Geometries

Coatings applied by thermal spraying are conformal, and can be sprayed over most complex and curved surfaces, provided the surface is accessible. Some commonly coated examples of complex surfaces include turbine blades and pump impellers.

Conclusion

Thermal spray coating offers a number of advantages for surface protection, including the ability to apply a wide range of materials, the ability to be applied very thinly, and the fact that it can offer substantial life extension to critical surfaces. If you're looking for an option that is resistant to high temperatures and that is adaptive to various shapes, then thermal spray coating is a perfect choice. Thermal spray coatings are depended upon in a variety of industries, including automotive, aerospace, and oil and gas. So if you're looking for an option that is versatile and durable, then thermal spraying is the way to go.

Hayden Corporation is the leading provider of thermal metal spray coatings in Massachusetts. We offer our coating services nationwide and in a variety of industries, including aerospace, military, and more. Our coatings are designed to provide superior durability and strength, and our team of experts is dedicated to providing the highest quality coating solutions possible. If you are in need of thermal spray coating, reach out to us today! We would be happy to discuss your specific needs and provide a quote for our services. Thank you for considering Hayden Corporation.