Thermal Spray
01.
What is Thermal Spray?
Thermal spray is a category of coating processes in which melted or heated materials are sprayed onto a surface to form a coating. The process involves feeding coating material—often in the form of powder, wire, or rod—into a high-temperature source such as a flame, plasma, electric arc, or combustion gun. Once heated to a molten or semi-molten state, the particles are propelled at high speed toward the target surface, where they flatten and solidify upon impact, creating a dense and adherent coating layer.
This technology is unique in that it allows for coatings to be applied with minimal thermal input to the substrate, making it suitable for components sensitive to heat distortion. Unlike other coating processes like electroplating or chemical vapor deposition, thermal spray does not require a vacuum chamber or reactive chemicals, offering operational flexibility and scalability.
The resulting coatings can be tailored in thickness, texture, and composition to match specific performance requirements, from corrosion resistance to high-temperature insulation. The variety of materials that can be used—including metals, ceramics, carbides, and polymers—further expands the application range.
02.
Key Industrial Applications Across Critical Sectors
Thermal spray is applied across numerous industries, where its ability to enhance surface properties leads to longer component life and improved system reliability. In the aerospace sector, for example, thermal spray coatings are used extensively on engine components, landing gear, and turbine blades. These coatings can provide wear resistance, thermal insulation, and oxidation protection under extreme operating conditions.
In the power generation industry, turbines, boilers, and heat exchangers are subjected to high temperatures and corrosive gases. Thermal spray coatings offer a layer of protection that prolongs service intervals and reduces unplanned downtime. This is especially relevant in gas turbines, where ceramic-based thermal barrier coatings (TBCs) enable engines to operate at higher temperatures without degrading structural integrity.
The automotive industry also benefits from thermal spray. Components such as cylinder bores, brake discs, and crankshafts are often coated to improve wear resistance, reduce friction, or enhance heat transfer. These improvements lead to more efficient engines, better fuel economy, and longer service life.
In oil and gas, the technology is used to protect pipelines, drilling tools, and pump components from corrosion, erosion, and extreme pressures. Thermal spray is similarly invaluable in heavy industry, including steel production, paper mills, and mining, where equipment faces constant wear and exposure to harsh chemicals.
Even the biomedical field has found value in thermal spray. Implants such as hip and knee replacements often receive hydroxyapatite coatings via plasma spray. This bioactive surface promotes better integration with bone tissue, reducing recovery time and improving patient outcomes.Our Solutions
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Thermal Spray Tapes
DW501
$38.00 – $76.00 Select options This product has multiple variants. The options may be chosen on the product page -
Thermal Spray Tapes
DW-503
$42.00 – $84.00 Select options This product has multiple variants. The options may be chosen on the product page -
Thermal Spray Tapes
DW-500
$34.00 – $68.00 Select options This product has multiple variants. The options may be chosen on the product page -
Thermal Spray Tapes
DW-410
$45.00 – $90.00 Select options This product has multiple variants. The options may be chosen on the product page -
Thermal Spray Tapes
DW-407
$14.00 – $56.00 Select options This product has multiple variants. The options may be chosen on the product page
03.
Selecting the Right Tape for the Process and Geometry
Before choosing a tape, consider two key factors:
a) The thermal spray process and
b) The surface geometry you need to mask.
Each spray method—plasma, flame spray, HVOF—comes with its own level of heat, particle velocity, and rebound pressure. For example, HVOF and plasma spray are more aggressive, requiring thicker, high-adhesion masking materials, while flame spray may be masked with lighter tapes.
DeWAL manufactures a versatile range of masking tapes tailored to these conditions:
DeWAL DW500 Series (Silicone Glass Cloth Tapes)
Ideal for flame spray and light-duty plasma jobs. Offers strong adhesion and clean removal, even after prolonged heat exposure.
DeWAL DW560 (Double-Ply Glass Cloth)
Best for high-velocity HVOF or aggressive plasma. Its two-layer laminate offers superior abrasion resistance and masking durability.
DeWAL DW245 (Aluminum Foil/Glass Laminate)
Designed for reflecting radiant heat, often used as an outer protective barrier in high-temp zones.
DeWAL DW409 (PTFE-Coated Glass Cloth)
Excellent for non-stick, clean-release applications. Perfect for sealing edges or overcoating other tapes.
The shape and complexity of the part also influences your tape choice. Flat surfaces are easily covered with glass cloth or foil laminate tapes, while complex edges, threaded holes, or tight cavities may require tape plus masking putty or silicone plugs. DeWAL’s tapes are flexible enough to conform but robust enough to resist movement under high-speed particle impact.
04
Key Performance Traits and Application Techniques
When evaluating thermal spray masking tapes, it’s important to think about real-world performance, not just specs on paper. The most effective tapes combine several critical properties:
| Requirement | Best DeWAL Tape(s) | Notes |
|---|---|---|
| High Adhesion | DW500, DW560 | Won’t lift during high-velocity spray |
| Direct Particle Resistance | DW560 | Ideal for repeated passes or direct hits |
| Clean Removal | DW409, DW500 | No residue left behind |
| Thermal Shielding | DW245 | Reflects radiant heat; pair with glass cloth |
| Conformability | DW409, DW500 | Works on uneven or curved surfaces |
For extra protection, many thermal spray shops layer tapes—for example, placing a PTFE-coated DW409 over DW500 to combine heat resistance with clean release. This also allows easy cleanup after complex coating runs.
Additionally, preparing the surface before tape application is vital. A clean, dry, lightly abraded surface ensures better adhesion, especially in plasma and HVOF environments where rebound pressure can lift masking tape if improperly applied.
Always run a test masking trial before full-scale production. The tape’s performance will vary slightly depending on your specific spray gun distance, particle flow, and part geometry.Importance of Thermal Spray
Extends Component Lifespan
Thermal spray coatings protect parts from wear, corrosion, oxidation, and high-temperature damage—significantly extending the service life of expensive components.
Improves Performance and Efficiency
Coatings can enhance thermal insulation, electrical conductivity, or friction control, allowing machines and engines to operate more efficiently under extreme conditions.
Reduces Maintenance and Downtime
By applying durable surface layers, thermal spray reduces the frequency of part replacement and maintenance, which helps minimize costly production interruptions.
Enables Surface Customization Without Altering Base Material
Thermal spray allows manufacturers to tailor surface properties—like hardness or resistance—without changing the core material, preserving the part’s original structural integrity.