Thermal spraying is a fast and effective coating technique that uses heated materials like metals, ceramics, and plastics to protect or repair surfaces. It can add several millimeters of material at once without using harmful VOCs and can melt metals, making it versatile.
Thermal spraying is a coating technique that sprays a heated material onto a surface to cover and protect it. Various materials can be used in thermal spraying, but the three most common are metals, ceramics, and plastics; before being heated, they can be in the form of rods, liquid or powder. Running a thermal spray can be done to protect or repair a surface material. One of the biggest benefits of using a thermal spray is that it can lay down a large amount of material very quickly. Unlike other coating methods, thermal spraying does not use volatile organic compounds (VOCs), the coating cools quickly, and materials that require high amounts of heat to melt can be used in the spray.
A thermal spray can be created using metal, ceramic, or plastic, the most common being metal and plastic. To create a thermal spray, the material, or raw material, is placed in a furnace which heats the material until it melts. The raw material can be added to the kiln in the form of a powder, rod, thread, or liquid, although liquid is not common.
One benefit of thermal spraying is that it coats a surface material with a protective barrier. For example, a surface coated with a strong metal will become more resistant to wear, heat, abrasion and, if the metal spray resists magnetism, magnetic forces. Another plus is that a heat spray can repair the surface material. A worn iron bar can be sprayed with iron to fill in the worn sections.
Many coating methods only apply several micrometers of material to a surface, which isn’t very effective if a lot of material is needed to adequately protect the surface. With thermal spraying, the spray can add up to several millimeters of material at once, which is significantly thicker. This means that spraying is usually finished in much less time.
Some coating materials and methods require the use of harmful VOCs that can affect people and the environment, but thermal spraying does not require any use of VOCs. The thermal spray technique forces the materials to cool rapidly, which allows the coating to settle in a short amount of time. Metal has a high melting temperature and many other spraying and coating techniques are unable to melt metal. Thermal spraying is capable of producing the high amounts of heat required, which allows operators to use a wider variety of materials.
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