Characteristics of Thermal Spray:

  1. Low temperature processing
  2. Low to high temperature service
  3. Relatively thin to very thick
  4. coatings possible
  5. Good adhesion to substrate
  6. Coarse to smooth finish –
  7. post machining possible
  8. Components can often be recoated –
  9. provides additional service life

Definition of Thermal Spray:  Thermal Spray can be defined as:

Group of processes where a material is heated (electric or combustion), atomized, and propelled unto a prepared substrate forming a coating.

What is Thermal Spray?

 Thermal spraying is an industrial coating process.  Thermal spray has a heat source (combustion or electric) and a coating material in a powder or wire form.  The heat source melts the power/ wire into tiny droplets (atomized) and sprays the material onto surface to form a coating.

There are several  processes:

  • Plasma Spray APS atmospheric plasma spray
  • HVOF (high velocity oxygen fuel)
  • HVAF (high velocity air fuel)
  • Arc Spray (twin wire arc spray for TSA TSZ)
  • Flame Spray (powder and wire)

Thermal sprayed coatings are typically applied to metal substrates, but can also be applied to some plastic substrates. Thermal sprayed coatings uniquely enhance and improve the performance of the component

  • Resist Abrasion, Errosion, 
  • Retard Corrosion
  • Manage Thermal Efficiency
  • Thermal barriers
  • Enhance Electrical Properties
  • Control Dimensions & Clearances
  • Build up worn parts
  • Salvage worn Components
  • Manage Bond Coats

Reduce Cost Through Surface Engineering:

  • Better Performance
  • Longer Component Life
  • Decreased Maintenance
  • Lighter weight component
mining applications in Thermal Spray
Thermal Spray in power industry
bexxon global pte ltd Indonesia

Typical Applications for Thermal Spray


  • Engine,
  • Landing Gear,
  • Actuator
  • Clearance Control/ Dimensional Restoration
  • Abradable
  • Thermal and Environmental Protections
  • Mechanical Wear Control

Power Equipment & Machinery:

  • Turbines, Compressors, Engines
  • Clearance Controll & Dimensional Restoration
  • Thermal and Environmental Protection
  • Mechanical Wear Control


  • Engine Block & Components
  • Cylinder bores,
  • synchromesh rings,
  • exhaust sensors,
  • fuel injection nozzles,
  • alternator caps,
  • piston rings,
  • stems and seats 
  • Mechanical, Thermal & Chemical Protection

Heavy Industry: Oil & Gas, Pulp & Paper, Steel, Mining, Chrome Replacement

  •     Mechanical Wear & Environmental Protection
  • Wear control, surface restoration, and salvage of paper calender rolls
  • Sealing, erosion and corrosion
  • Controls of pumps & valves