A thermal spray coating is typically applied to a substrate to increase its wear resistance and protect it against corrosion when used in challenging environmental conditions, but with various thermal spray coating methods available, it can be tricky to decide which to use.
Two common thermal spray coating methods
Plasma spray and flame spray are different thermal spray coating methods delivered by companies such as https://www.poeton.co.uk/surface-treatments/thermal-metal-sprays. Though they deliver a similar outcome, they do so in different ways and are suited to different applications.
Plasma spray
Plasma spray uses an ionised gas called plasma to create a high-velocity flame that is used to melt a powdered coating material and accelerate it onto the substrate, where it cools quickly to create a dense, strong coating. This method can be used on a variety of different substrate materials including ceramics.
Flame spray
Flame spray uses a mixture of oxygen and fuel gas to generate a flame that melts the powder or wire coating material that is then applied to the substrate using compressed air where it cools into a protective coating.
Key differences
The main differences between the two methods are cost, temperature, performance and ease of application. Flame spray is cheaper and applied at a lower temperature. The substrate requires less preparation for flame spraying than for plasma spraying but the coating applied is more porous and less durable.
Plasma spray is applied to rigorously prepared substrates at exceedingly high temperatures, attracting a higher cost but delivering a more durable and long-lasting finish.
