Thermal spraying is a cost-effective way to improve the durability and performance of components. It's not always practical to fabricate a component entirely out of a heat-resistant, corrosion-resistant and chemical-resistant material, but adding a thermal coating is a low-cost technique to protect your application. Thermal coating, sometimes called metallizing, begins with material feedback, typically a powder, which is then melted by an electric or flame source. The melted material is then accelerated onto the application's surface, where the material impacts and coats the surface.

A variety of materials and techniques are used in thermal spraying. Popular thermal spraying materials include ceramics, aluminum, stainless steel and cermets. Thermal spraying is used in a wide range of industries, including automotive, aerospace, food-processing, construction, marine and oil and gas. When contracting thermal spraying services, consider the following:

1. Use plasma thermal spraying for outdoor structures.

2. Implement thermal flame spraying for general applications without resistant qualities.

3. Coat your applications with ceramics when you need electrical insulation.

4. Contract thermal spraying companies with experience in your industry.

Action Steps
The best contacts and resources to help you get it done

Utilize plasma thermal spray technology

Plasma thermal spraying is an ideal technology for structural elements, such as bridge and pier components, that are exposed to nature. Plasma spraying can use a variety of materials for the thermal coating. The material is introduced to the plasma jet where it is melted and sprayed.

I recommend: Contact Associated Wear Coatings for full-service thermal spraying, including plasma spray coating. The company has the ability to spray any available powder of the correct mesh size. Find plasma spray coating services at White Engineering. The company's capabilities include plasma spray carbide, plasma spray pure metal and metal alloy, plasma spray thermal barrier and plasma spray ceramic coatings.

Contract thermal spray companies that use thermal flame spraying

Thermal flame spraying is recommended when working with materials that could distort in extreme temperatures. The thermal coating is melted in a flame, and then applied to the application. The application is typically ready for operation in a few hours.

I recommend: Southwest United Industries offers thermal flame spraying and frequently serves the aerospace and the oil and gas industries. Find a broad inventory of wires and powders for flame spray applications at Industrial Grinding. The company's thermal spray coating services are ISO 9001 certified.

Implement a ceramic coating of thermal spray

Ceramic thermal coatings are extremely resistant to wear and tear, corrosion and heat. If your application requires electrical insulation, a ceramic coating is your best option. Ceramic thermal spraying is often used in the aerospace and automotive industries.

I recommend: Cincinnati Thermal Spray offers on-site thermal coating services. The coating types include ceramics such as chromia and titania oxide. Contact MBL for ceramic thermal coating. The thermal spray company uses an online advisor to determine the best services for your application.

Use thermal spray companies experienced with your application

Contracting thermal spray companies that routinely work with your specific application ensures the proper materials and technique will be used. Whether your application is food-processing equipment or a canal, make sure the thermal spraying company has experience in your industry.

I recommend: Flame Spray specializes in flame spraying services for the power plant and aerospace industries. Platt Brothers & Company offers thermal spray materials designed specifically for steel highway bridges, walkways, bridge bearing railings, piers, waterways, gates, gas cylinders, boat trailers and other marine equipment.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  A plasma thermal spray finish can potentially damage applications that can't tolerate very high temperatures. If your application isn't heat resistant, use a flame spraying technique to apply the thermal coating.