Thermal Spray is a generic term for a group of coating processes used to apply metallic, carbide and non-metallic coatings to a wide variety of materials.

The process uses a spray gun in which the coating material is heated to a molten or semi-molten state by using electricity or gases. The heated particles are then accelerated and propelled toward a prepared surface by either process, gas or atomization jets.

Upon impact, a bond forms with the surface and subsequent particles cause thickness buildup. Unlike welding, there is no distortion to the piece being worked on caused by excessive heat. Thermal spraying applies to two basic types of coatings:

Wear resistance coatings provide barriers resistant to abrasion, corrosion, erosion, fretting, friction or galling. Such coatings provide the sprayed items with a longer life than bare metal or painted surfaces.

Resurface coatings are used to rebuild worn areas, salvage improperly machined parts or improve the characteristics of newly machined parts. Properly selected materials used in resurface type coatings often result in parts that exceed the projected lifespan of original manufactured materials.