Thermal spray equipment accelerates the dispersion of heated coating material from a spray torch towards a workpiece. The deposited material forms a coating on the surface. In thermal deposition or thermal spraying applications, thermal spray equipment is used to apply molten or softened particles to a cold surface (usually metal, but sometimes plastic) at high velocities. Important parameters to consider when selecting thermal spray equipment include coating density, bond strength, degradation during the coating process, substrate heating, surface finish, wear and corrosion resistance of the finished product, and cost. In many industries, thermal spray equipment is used to protect engineering components from harsh conditions such as extreme temperatures and exposure to corrosive substances.
Thermal spray equipment includes many different types of powder coating equipment. In wire arc thermal spraying, material is melted in an electric arc and sprayed towards the work piece to form a coating. In combustion wire thermal spraying, a wire or rod is melted in a flame and sprayed towards the workpiece. Combustion powder thermal spraying is similar to combustion wire thermal spraying, except that the material to be deposited is in powder form. This allows a wide range of materials to be deposited. In arc wire (or wire arc) thermal spraying, two electrically charged wires are fed to the spray gun. When they strike an electric arc, they vaporize. In plasma spray coating, a powder is injected into plasma, where it is rapidly heated and sprayed onto the substrate, where it cools rapidly. In hypervelocity oxyfuel coating or HVOF coating, the combustion of fuel with oxygen produces a very hot, high-pressure flame, which is used to spray the powder toward the workpiece. In detonation spray coating (DSC), the repeated detonation of a gas mixture sprays a powder at high temperature and velocity towards the workpiece. In cold spraying coating, high pressure compressed gas sprays fine powder at very high velocities (500 - 1500 m/s) onto the workpiece.
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