Thermal Spray Coating Systems

TAFA Thermal Spray Coating Systems

Thermal Spray Coating Systems you can't beat

While each process is unique in how they produce a thermal spray coating, each method has five main components in the thermal spray system:

  • An appropriate process control console or similar devices for controlling the gases, liquids and electrical current used by the thermal spray process
  • An appropriate gun for producing a hot gas stream for heating, accelerating, and directing flow of thermal spray material towards a substrate
  • An appropriate feedstock material conveyance device for delivering feedstock to the thermal spray gun
  • Feedstock (powder, wire, rod, or cord) fed at appropriate velocity to allow spray gun to melt them
  • Controlled coating application area atmosphere

We are a world leader in thermal spray equipment and coating technologies. We didn’t get that designation by accident. We have spent the last 50 years researching, developing and improving our solutions to deliver the best coatings possible. Learn more about our TAFA® brand thermal spray coating systems below.

Of all our thermal spray processes, arc spray offers the best combination of reliability, versatility and affordability. Our complete family of TAFA arc spray products uses tailored technology to deliver the coating solution you want. From push to pull to innovative process enhancements, we offer the best configuration for even your most demanding applications.

Our TAFA HVOF product line offers both liquid-fueled high-pressure/high velocity oxygen fuel (HP/HVOF)® and gaseous-fueledHVOF systems. Our liquid-fueled HP/HVOF systems are designed to produce high-quality, ultra-dense coatings at exceptionally high production rates. And our gaseous-fueled HVOF systems bring together our sophisticated yet easy-to-use controls technology and renowned safety design to produce high-quality, repeatable HVOF coatings.

When it comes to plasma spray, consistent performance at any energy level is the highest priority. To give you ultimate control over your operations, we offer a complete range of TAFA plasma spray systems from low-energy manual critical orifice controlled to high-energy computerized mass-flow controlled.

What is Thermal Spray used for?

Thermal spray is a technology in which a material is heated and then applied to a prepared substrate as a spray of molten or semi-molten droplets which harden to form a protective coating. A thermal spray coating improves, restores, and enhances a substrate's surface. Thermal spray coatings are commonly used in electronic, aerospace, mechanical and automotive industries to provide corrosion and wear protection. 

There are five main steps in a thermal spray coating process:

  • Substrate preparation
  • Generation of the energetic gas flow
  • Feedstock (particle, wire, rod, cord) injection
  • Gas particle or droplet interaction
  • Coating formation

There are many processes of thermal spray coatings systems: twin-wire arc, HVOF, plasma spray, and combustion (flame) spray. All thermal spray coating systems have the following in common: 

  • Thermal spray transfers relatively low heat to the substrate that is sprayed
  • Thermal spray is a mechanical bonding process
  • Thermal spray offers a wide range of materials that can be used: steels, stainless steels, nickel alloys, pure metals (like aluminum, zinc and copper), bronzes, ceramics (chrome oxide, aluminum oxide, zirconia, and titania), tungsten carbides, titanium, etc. 
  • Thermal spray coatings can be applied with various coating properties and at various thicknesses

What is Thermal Spray powder?

Thermal spray powder essentially refers to the powder material that will be melted down and then applied to a prepared substrate to form a protective coating. Powders for thermal spray are produced four main ways: atomization, chemical, electrolysis, and solid state reduction.

Examples of common metal powders used include zinc, tin, nickel, iron, granular copper and aluminum powder. However, since not all thermal spray processes involve metal powder, there are also plastics, ceramics and alloys and composites available to be thermal sprayed on a surface.

Praxair Surface technologies offers a complete line of powders for thermal spray applications and additive manufacturing