Fundamentals Of:

Hot Metalizing/Thermal Spray

Prepared by:
Md Asifur Rahman Prantik
Assistant Engineer(Technical Service)
RotoTech Bangladesh Ltd.
Table of contents

01 02
Fundamental Theory of Coating type, Application &
Thermal Spraying(Hot Characteristics of Different
Metalizing) Types of Thermal Spray
Technology

03 04
Metalizing/Thermal Spray
Materials and their useful Metalizing Devices
Implication in the context of
RotoTech Services
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1
Fundamental Theory
of Thermal
Spraying(Hot
Metalizing)
What is Hot Metalizing/Thermal Spray
Hot metalizing, also known as thermal spray coating, is a surface engineering process in which a coating material is
melted or heated to a molten/semi-molten state and then sprayed onto a substrate to create a protective or functional layer.

Basic Working Principle of Thermal Spray:

The basic working principle of the thermal spraying process
involves melting a feedstock material (in the form of powder,
wire, or rod) and propelling the molten or semi-molten particles
onto a prepared substrate to form a coating. The process
begins with the energy source (flame, electric arc, plasma arc,
or combustion gases), which generates the heat required to
melt the feedstock. The feedstock material is fed into the spray
gun through feed mechanisms like wire spools or powder
feeders. Simultaneously, carrier gases (e.g., air, nitrogen, or
argon) or compressed air propel the molten particles at high
velocities toward the surface. The substrate is usually pre-
treated (e.g., grit blasting) to enhance mechanical interlocking
and adhesion. As the molten particles impact the surface, they
flatten, cool rapidly, and build up layer by layer to form a dense,
cohesive coating. The process is controlled by adjusting key
parameters such as temperature, velocity, spray distance,
Fig: Basic Working Principle of Hot Metalizing
and feed rate, ensuring coating properties match the intended
application.
Basic Terminologies of Hot
Metalizing/Thermal
Before Spray
going deeper into Hot Metalizing/Thermal Spray we must have to know the basic terminology
associated with it. Those are:
Substrate: The base material onto which the coating is applied. This could be metal, ceramic, or
plastic, depending on the application.
Spray Plume: The stream of hot, molten or semi-molten particles generated during the thermal
spraying process. It is formed by the interaction of the spraying material with the heat source, and it
carries the feedstock material toward the substrate.
Feedstock Material: The material that is fed into the thermal spray system and is melted or partially
melted to be sprayed onto the substrate. It can be in the form of powder, wire, or rod, depending on the
thermal spraying process used.
Coating: The layer of material deposited on the substrate via the thermal spraying process. It’s used for
protection (e.g., corrosion or wear resistance), for enhancing appearance, or for functional improvements.
Substrate Preparation: The process of cleaning and roughening the substrate to ensure good
adhesion of the coating. It often includes processes like grit blasting.
Deposition Rate: The speed at which the material is deposited onto the substrate during the spraying
process.
Adhesion Strength: The force required to break the bond between the coating and the substrate,
indicating the quality of the coating’s adhesion.
Fundamental Classification of Thermal Spray/Hot
Metalizing
Knowing the fundamental classification of thermal spray is very important on the context of different
application of it in different technological context and concept. Some of them are:

Flame Spraying

Plasma Spraying

High Velocity Oxygen

Hot Metalizing/Thermal Spray
Fuel (HVOF) Spraying

Cold Spraying

Detonation gun Spraying

Arc Spraying
Details Explanation of Different types of
Thermal Spraying
Flame Wire Spraying
Flame Spraying
Flame Powder Spraying

The flame wire spray process involves feeding a In the flame powder spray process, a powdered
metallic wire (the feedstock material) into a high- feedstock material is fed into an oxy-fuel flame
temperature oxy-fuel flame, where the wire tip melts generated by the combustion of fuel gas (e.g., propane
due to the heat generated by the combustion of fuel or acetylene) and oxygen. The powder particles are
gas (e.g., acetylene or propane) and oxygen. Once melted or softened as they pass through the flame.
melted, compressed air is used to atomize and Compressed air or the flame itself then propels the
propel the molten droplets onto the substrate, where molten particles toward the substrate, where they
they solidify to form a coating. solidify to create a coating..
 Arc Spraying Cold Gas Spray

Cold gas spraying (also known as cold spraying) is a

Arc spraying is a thermal spray process that uses an electric thermal spray process that operates at relatively low
arc as the heat source to melt metallic feedstock materials, temperatures, below the melting point of the feedstock
typically in the form of two wires. The wires are continuously material. In this process, fine particles of the feedstock
fed into the arc, where they melt due to the high temperature
generated by the electrical discharge. Compressed air or
material (typically metals or alloys) are accelerated to
another gas is then used to atomize the molten material into supersonic speeds using a high-pressure gas, such as
fine droplets and propel them toward the substrate, where they nitrogen or helium, through a converging-diverging
solidify upon impact to form a coating. Arc spraying is widely nozzle. Upon impacting the substrate at high velocity,
used for applying metallic coatings for corrosion protection, the particles undergo plastic deformation and adhere
wear resistance, or surface restoration due to its cost- to the surface without melting, forming a dense and
effectiveness and ability to deposit coatings quickly over large
areas.
strongly bonded coating.
 High Velocity Oxygen Fuel (HVOF) Plasma Spray

High-Velocity Oxygen Fuel (HVOF) spraying is a thermal spray Plasma spray is a thermal spray process that uses a high-
process in which a mixture of fuel gas (e.g., propane, temperature plasma arc as the heat source to melt the
kerosene, or hydrogen) and oxygen is combusted in a high- feedstock material, which is usually in powder form. A plasma is
pressure chamber to produce a high-temperature, high-velocity generated by ionizing a gas, such as argon, nitrogen, or a
flame. The powdered feedstock material is injected into this mixture, using an electric arc inside a plasma torch. The
flame, where it is heated to a molten or semi-molten state and resulting plasma jet reaches temperatures as high as 15,000°C,
accelerated to supersonic speeds. The particles are propelled making it suitable for melting materials with extremely high
toward the substrate, where they flatten and solidify upon melting points, such as ceramics and refractory metals. The
impact, forming a dense, strongly bonded coating. HVOF powdered feedstock material is injected into the plasma jet,
spraying is widely used for producing coatings with excellent where it is melted and propelled toward the substrate at high
wear resistance, corrosion resistance, and high bond strength, speed. Upon impact, the molten particles flatten and solidify,
making it suitable for demanding applications in industries like forming a dense and durable coating.
aerospace, power generation, and oil and gas.
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2
Coating type,
Application &
Characteristics of
Different Types of
Thermal Spray
Coating type, Application & Characteristics of Different
Types of Thermal Spray Technology
Flame Wire Spraying Flame Powder Spraying Arc Spraying

Typical Coatings: Typical Coatings: Typical Coatings:

1.Iron-based alloys 1.Self-fluxing alloys (fusing) 1.Iron-based alloys
2.Nickel-based alloys 2.Iron-based alloys 2.Nickel-based alloys
3.Molybdenum 3.Nickel-based alloys 3.Copper & Copper alloys
4.Copper & Copper alloys 4.Ceramics & Cermets 4.Aluminium, Zinc, Al/Zn alloys
5.Aluminium, Zinc, Al/Zn alloys 5.Abradables 5.Babbitt alloys
Main Application: Main Application:
1.Wear resistance 1.Wear resistance
Main Application:
2.Friction properties 2.Corrosion protection
1.Wear resistance
3.Corrosion protection 3.Chemical resistance
2.Corrosion protection
4.Dimensional restoration 4.Dimensional restoration
3.Dimensional restoration
5.Electromagnetic shielding Characteristic: 4.Bond coat
Characteristic: The main advantage of this process is
Heat source creates gas steam with a that a much wider range of materials
temperature of 3000 C (such as nickel or cobalt-based self- Characteristic:
fluxing alloys or ceramic materials) Electric Arc creates temperature
can be easily processed into powder around 4000 C melt the two wire
form giving a larger choice of
coatings.
Coating type, Application & Characteristics of Different
Types of Thermal Spray Technology
HVOF Cold Gas Spraying Plasma Spraying

Typical Coatings: Typical Coatings: Typical Coatings:

1.Triballoy, Inconel 1.Ductile materials & alloys, Zn, Al, Ni, 1.Ceramics
2.Iron-based alloys, AISI 316L, etc. Ti, Cu, Ag, NiCr, CuAl, MCrAlY’s, etc. 2.Carbides & Cermets
3.Carbides & Cermets 3.Iron, Nickel & Cobalt based alloys
4.MCrAlY(M=Base metal,Cr-Chromium,Al- 2.High-end materials: Niobium or 4.Abradables
Aluminium,Y-yttrium) Tantalum Main Application:
5.Nickel&Cobalt based Alloy,Stellite
Main Application: 1.Wear resistance, Sliding, Abrasive,
Main Application: 1.Electrical and thermal conductivity 2.Erosion, etc
1.Wear resistance Sliding, 2.Pre-placement of solders 3.Corrosion resistance
2.Abrasive, Erosion, etc. 3.Corrosion protection 4.Thermal barriers
3.Chemical resistance 4.Dimensional restoration 5.Combinations
4.High-Temperature applications Characteristic:
Characteristic:
Characteristic: The coating material particles are Plasma created by argon only it
Have High coating density and low oxide being accelerated in a heated gas requires a very large arc current
formation due to high velocity of system stream (600 °C), up to a particle (Typically 800 to 1,000 amps) to
velocity of >1200m/s. create sufficient power to melt most
materials
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3
Metalizing/Thermal
Spray Materials and
their useful
Implication in the
context of RotoTech
Feedstock materials which are used in different types of Thermal Spraying Technology
Different types of common materials used in thermal spraying including their properties,advantages &
typical application
Different types of common materials used in thermal spraying including their properties,advantages &
typical application(continues)
Key Materials for the context of RotoTech Service Criteria Implementation
Key Materials for the context of RotoTech Service Criteria Implementation(cont.)
 SUPERALLOYS
A superalloy is a high-performance metallic alloy designed to exhibit exceptional mechanical strength,
resistance to thermal creep deformation, excellent corrosion and oxidation resistance, and stability at
elevated temperatures (often exceeding 1,000°C or 1,800°F). These properties make superalloys critical
for use in extreme environments, such as gas & steam turbines, turbochargers, jet engines, and power
plants. Some superalloy examples are given below:
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Metalizing Devices
 Flame Spray Devices

Metallisation
MK-61-FS
 Flame Spray Devices
Sulzer
Metco 5P-II
 Arc Spray Devices
Metallisation
Arc 140
TAFA JP-5000 HVOF Spray Devices
 HVOF Spray Devices
Sulzer Metco DJ2600
 Plasma Spray Devices
Sulzer Metco 9MB
 Cold Spray Devices
Impact Innovation 5/11
 Best choice for RotoTech

Device Selection
Implementation of different
material for different thermal
spraying technology
Comparison Table
 Thank
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