System Comparisons

System Comparisons

This are system comparisons of Thermal Spray Coating Systems. The systems that we will compare are  combustion wire, combustion powder, twin wire electric arc, HVOF, and plasma.

Each of the thermal spray processes have their specific area where they have the best properties for specific applications. It is best to evaluate the material properties required and the economics involved to be sure to select the correct process.

The chart below is brief overview of the different common thermal spray processes.

System Combustion Powder Comustion Wire Electric Arc HVOF Plasma
Energy Source acetylene/oxygen acetylene/oxygen electric arc propane-propylene/oxygen plasma “flame” with argon-hydrogen-nitrogen
Material Best Sprayed powder metals, alloys, fusible coatings wire metals, alloys wire metals, alloys carbides, metals, alloys, fusible coatings ceramics, bond coat
Secondary materials ceramics, carbides cored wires, cored with select powders like carbide carbides, metals, alloys
Cost less than $6,000 less than $8,000 less than $25,000 less than $40,000 less than $100,000
Advantages low cost, easy to use, wide material selection, low operating cost low cost, easy to use, lower cost materials, low operating cost easy to use, high spray rates, lowest operating cost densest coatings, outstanding for carbides highest energy “flame”, outstanding for ceramics
Disadvantage powders generally cost more than wire, ceramics and carbides less dense than HVOF and plasma limited to materials made in wire high initial cost, limited to materials made in wire high initial cost, high heat, higher training time, noise, high consumption of gases highest initial cost, most complex process, long training time, noise