What is Thermal Spray?

Protecting components from wear, corrosion, and extreme temperatures is essential for manufacturing and industrial operations. Thermal spraying is a versatile surface coating process that manufacturers use to enhance component performance and extend service life across various applications, from aerospace turbines to automotive parts.

Related: What is additive manufacturing?

Understanding Thermal Spraying

Thermal spraying is an advanced coating technology that deposits melted or heated materials onto a substrate surface to create protective or performance-enhancing layers. This versatile surface engineering solution can apply various materials, including metals, alloys, ceramics, and carbides, to protect components from wear, corrosion, and thermal damage. Unlike traditional coating methods, thermal spray technology allows precise control over coating thickness and properties while maintaining the substrate's integrity.

How Does Thermal Spray Work?

The Thermal Spray Process

To begin the thermal spray process, the coating material — typically in powder or wire form — is fed into a spray device, which is heated to a molten or semi-molten state. High-velocity gases then propel these heated particles toward the prepared substrate surface. Upon impact, the particles flatten and solidify, building up layer by layer to form a strongly bonded coating. This process occurs rapidly, with minimal heat transfer to the substrate, preventing distortion or changes to the base material's properties.

Thermal Spray Coating Techniques

Different thermal spray methods provide unique advantages that make them suitable for specific coating requirements and operating environments:

• Cold Spraying - Utilizing supersonic jets of compressed gas, our proprietary LOXPlate™ cold spray process efficiently applies high-density, low-oxygen coatings onto components for restoration and corrosion protection. This method is well-suited for the automotive and electronics industries due to its effectiveness in large surface areas and anti-corrosion applications.
• Detonation Gun & Super D-Gun™ - Combining gas and powder in controlled detonations, these methods create coatings with outstanding bond strength and density, typically using tungsten carbide or chrome carbide powders with a range of metallic binders.
• Flame Spraying - Applies a variety of high-melting temperature materials and is ideal for bond coat applications, such as applying molybdenum for automotive parts to enhance surface performance.
• Arc Spraying - Provides reliable, versatile, and cost-effective wire feedstock coating solutions. This method is particularly effective for large surface areas and anti-corrosion applications.
• High Velocity Oxy-Fuel (HVOF) - Produces dense coatings with superior bond strength and wear resistance. It is ideal for precision components requiring maximum durability and is available in both liquid and gas-fueled configurations.
• Plasma Spraying - Offers the highest coating quality and versatility. It can process virtually any sprayable material at extreme temperatures. This technique excels in applying ceramic coatings and complex material combinations.

Materials Used in Thermal Spraying

Thermal spray processes use a variety of materials engineered for specific performance requirements. Each material type offers distinct benefits for various industrial applications:

• Carbide Powders - Deliver extreme wear and corrosion resistance, making them ideal for components subject to severe abrasion and harsh chemical environments.
• Ceramic Materials - Provide exceptional thermal barriers and wear protection, particularly valuable in high-temperature applications where thermal management is crucial.
• Metal and Metal Alloy Powders - Offer versatile solutions for corrosion protection, dimensional restoration, and wear resistance. These materials, including cobalt, nickel, and iron-based alloys, provide excellent oxidation resistance and coating durability.

Benefits of Thermal Spray Coatings

Enhanced Wear Resistance

Thermal spray coatings prevent early degradation by creating highly wear-resistant surfaces. These coatings can withstand severe abrasion, erosion, and friction, making them valuable for manufacturing, mining, and heavy industry applications. Selecting from various coating materials allows engineers to optimize wear resistance for specific operating conditions.

High-Temperature Stability

Thermal spray coatings provide exceptional thermal protection for components exposed to extreme temperatures. Ceramic thermal barrier coatings can withstand temperatures exceeding 2000°F while maintaining their protective properties. This capability is especially useful in aerospace and power generation applications, where components must perform reliably under intense thermal stress.

Corrosion Protection

Industrial environments often expose components to corrosive chemicals, moisture, and atmospheric conditions that rapidly corrode unprotected surfaces. Thermal spray coatings create a robust barrier against corrosion, significantly extending equipment life and reducing maintenance costs. Depending on the application requirements, these coatings can be engineered to provide both active and passive corrosion protection.

Industries with Thermal Spray Applications

Aerospace and Aviation

Thermal spray coatings protect critical engine components from extreme temperatures and wear. Turbine blades, combustion chambers, and landing gear benefit from specialized coatings that enhance thermal resistance and durability. These coatings help maintain strict safety standards while extending component life and reducing maintenance frequency.

Power Generation

Power plants rely on thermal spray coatings to protect turbine components from high-temperature oxidation and hot corrosion. Boiler tubes, heat exchangers, and gas turbine parts receive specialized coatings that improve efficiency and extend service intervals. These protective layers help maintain optimal operating conditions while reducing downtime and replacement costs.

Oil and Gas

The harsh environments in oil and gas extraction and processing demand exceptional component protection. Thermal spray coatings protect drilling equipment, valves, and pumps from corrosion, erosion, and wear. These specialized coatings help maintain equipment integrity in challenging conditions, from offshore platforms to refineries.

Manufacturing and Industrial

Manufacturing operations benefit from thermal spray coatings that enhance wear resistance and reduce friction on production equipment. Components like rollers, shafts, and machine parts receive custom coating solutions that improve performance and extend operational life. These applications help maintain production efficiency while reducing maintenance costs.

Automotive

The automotive industry uses thermal spray coatings to enhance component performance and durability. Coatings that provide wear resistance and thermal protection benefit engine parts, transmission components, and brake systems. These applications help improve vehicle reliability while meeting stringent performance requirements.

Semiconductors and Electronics

In semiconductor manufacturing, high-purity thermal spray coatings protect components from contamination and wear. Process chamber components and handling equipment receive specialized coatings that maintain clean room standards and ensure consistent production quality. These applications help protect sensitive electronic components while maintaining manufacturing precision. 

Linde AMT's Thermal Spray Solutions

Thermal Spray Coating Services

We employ advanced robotic thermal spray systems to precisely apply diverse coating materials - from high-temperature oxides to tungsten-carbide and copper-nickel-indium composites. Our automated multi-axis equipment ensures uniform coverage even on complex geometrical surfaces while allowing customizable spray rates and thicknesses. The resulting coatings provide superior protection in extreme operating conditions.

Specialized Powders for Thermal Spraying

Linde manufactures over 500 different powder chemistries and maintains a stock of 300 standard formulations, ensuring the right material for any application. Our rigorous quality control processes and advanced manufacturing techniques, including vacuum induction melting and controlled atmosphere processing, deliver consistent, high-performance coating materials that meet the most demanding specifications.

Advanced Coating Equipment and Support

Our thermal spray systems deliver reliability and precise control through integrated state-of-the-art monitoring and automation capabilities. From basic manual systems to fully automated robotic installations, we provide complete coating solutions backed by comprehensive technical support, training, and maintenance services. Our equipment options include customizable dust collection systems, acoustic enclosures, and sophisticated manipulation systems for optimal coating results.

Why Partner with Linde?

Choosing Linde as your thermal spray technology partner gives you access to decades of material science expertise, proven coating solutions, and comprehensive technical support. Our vertically integrated approach — from powder manufacturing to equipment design and application support — ensures consistent quality and optimal performance for your coating requirements. Whether protecting aerospace components or enhancing industrial equipment durability, our experts work closely with you to develop and implement the ideal thermal spray solution for your needs. Contact our technical specialists today to discover how Linde can enhance your component performance and operational efficiency.

Related: What are solid oxide fuel cells?

FAQs

What surfaces can thermal spraying be applied to?
Most metallic and non-metallic materials can receive thermal spray coatings, provided proper surface preparation is performed.

What industries commonly use thermal spray coatings?
Aerospace, automotive, power generation, oil and gas, and general manufacturing industries regularly utilize thermal spray coatings.

How long do thermal spray coatings last?
Coating longevity depends on operating conditions and maintenance practices, but properly applied coatings can extend component life significantly compared to uncoated parts.

Can thermal spray coatings be repaired?
Yes, most thermal spray coatings can be repaired or reapplied after proper surface preparation, making them a cost-effective long-term solution.