Thermal Spray
High-performance thermal spray coatings that extend part life up to 4x compared to conventional methods.
What Is Thermal Spray?
Thermal spray is an advanced surface coating technology that produces extremely dense, well-bonded coatings with superior hardness and wear resistance. The process accelerates coating particles to supersonic velocities, creating a coating with exceptional density, adhesion, and mechanical properties.
Unlike conventional coating and thermal spray methods, our process produces coatings with significantly lower porosity (typically less than 1%), higher bond strength (exceeding 10,000 PSI), and greater hardness — translating directly into longer part life, better surface quality, and improved performance.
Thermal Spray Process
Watch our advanced thermal spray coating process in action.
Thermal Spray Coating Benefits
- Up to 4x longer part life compared to chrome plating or conventional thermal spray
- Extremely low porosity (less than 1%) prevents corrosion and material infiltration
- Superior bond strength exceeding 10,000 PSI ensures coating integrity under heavy loads
- Hardness values of 1100–1400 HV provide exceptional wear resistance
- Environmentally friendly alternative to hard chrome plating (no hexavalent chromium)
- Consistent, uniform coating thickness for reliable performance
- Can be applied to new parts or used to refurbish worn components
- Cost-effective over the total lifecycle despite higher initial investment
Applications Across Industries
Thermal spray coatings are used across a wide range of industries and roll types — including bridle rolls, looper rolls, deflector rolls, sink rolls, and pot equipment. In the steel industry, thermal spray-coated rolls resist extreme wear and thermal cycling. In aluminum processing, thermal spray coatings protect rolls from abrasive aluminum oxide and high temperatures.
Our service includes complete part preparation, masking, coating application, grinding to final dimensions, and quality inspection. We work with customers to select the optimal coating material, thickness, and surface finish for each application.
Interested in Thermal Spray?
Find out how our advanced thermal spray coatings can extend the life of your critical components.
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