Thermal Spraying Processes

Powder Flame Spray


Material in powder form is melted in a flame (Oxy-Acetylene or Hydrogen most common) to form a fine spray. When the spray contacts the prepared surface of a substrate material, the fine molten droplets rapidly solidify forming a coating.

The main advantage of this process over the similar wire flame spray process is that a much wider range of materials can be easily processed into powder form giving a larger choice of coatings.

Characteristics of Powder Flame Spray :

Material Form Powder
Heat Source Oxy-Fuel Combustion
Flame Temperature (°C) 3000
Particle Velocity (m/sec) < 300
Porosity (%) 10 to 15
Coating Adhesion (MPa) 14 to 21

Advantages :

  • High production spray rates
  • Easy to operate & portable
  • Large choice of coating materials
  • Can be easily automated

Disadvantages :

  • Porosity in the range of 10 - 15%
  • Lower bond strength in comparison to other process
  • High oxide level for metal deposits


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