When you need thermal spray coating services done in the Kennedale area or around the South and Southwestern United States, you can trust your local experts at Wear Master, Inc. Our team is equipped with state-of-the-art equipment to tackle your thermal spray coating and finishing projects. We utilize robotic technology to help us provide a uniform application and provide a higher quality end result for your machinery. You’ve invested too much in your machinery to leave it exposed to heat, weather, wear and tear — assure peak performance and the longest useful life possible from your business’ critical equipment by protecting with our thermal spray coatings.


Benefits Of Thermal Spray Coating

Thermal spray coating is one of the best upgrades you can get for the machinery for your shop, as it provides a range of benefits that not only save you money in the long term, but enhance the performance, durability, and value of your equipment.

When you choose Wear Master to apply thermal spray coatings to the machinery in your warehouse, you’re setting your business up for reduced costs down the line. Repairing a worn machine with thermal spray is cheaper than outright replacing the equipment itself, and thermal spray coatings often last longer than the material the component was originally composed of. Thermal spray coatings extend the useful life of machinery. In some case studies, they’ve been found to extend machine’s useful lives by as much as five times!

You don’t have to worry about thermal spray coatings altering your equipment’s functioning, either. Thermal sprays are extremely versatile and can be applied to practically any metal, ceramic, or plastic component. Thermal sprays have a low heat input — with very few exceptions, thermal spray coatings will leave alone the thermal history of the component(s) they are applied to. Thermal spray coatings can also be applied in a variety of thicknesses. Depending on the material and condition of the component being sprayed, thermal spray coatings can be sprayed from one-thousandth of an inch to more than an inch thick. Thicknesses typically range from 0.005 to 0.1 inch. The thermal spray coating application process is also relatively quick. Thermal spray rates range from three to 60 pounds an hour depending on the type of spray and the material and condition of the component(s) being sprayed. For most materials, spray rates fall between half a pound to two pounds of material per square foot per one-hundredth of an inch thickness.

Thermal sprays also provide your machinery various levels of resistance to heat, weather, and wear and tear, depending on the type of thermal spray you choose. Wear Master offers four types of thermal spray coatings: plasma spray, HVOF coating, electric arc wire spray, and combustion thermal spray coating. You can learn more about each type of thermal spray coating by visiting their service pages under the Our Services tab or continuing reading below.

Plasma Spray Coating

The plasma spray coating process involves melting powders that are fed into a plasma flame, created by inert gas. From non-ferrous alloys to stainless steels, ceramics, and aircraft materials, many surfaces can be treated by plasma spray due to its versatility. Most of the flame gases include argon, nitrogen, helium, or some combination of these three. While this method was originally designed for the aircraft industry, many other industries have chosen to protect their machinery with plasma spray due to the wear, heat, and corrosion resistance it provides once complete. These spray coatings are quite dense with higher bond strengths, and they don’t always need a bond coating.

HVOF Coating

The HVOF coating process requires a high-velocity flame, which is the key to the properties of the coating it creates. These coats are dense, hard, and well-bonded. These thermal sprays do not require bond coats, and they can easily be applied on top of other thermal spray coats when necessary. This fast-growing application has become the replacement for chrome plating, as it produces improved wear-resistance and thickness. With robotic and mechanical controls taking the lead on this process, you can expect both increased efficiency and repeatability for future projects with machines protected by HVOF coating.

Electric Arc Wire Spray

To apply electric arc wire spray coatings, our electric arc gun takes two wires simultaneously to a nozzle where the arc melts the wires. From there, the wires arc and melt, then they are applied onto the equipment with compressed air. Electric arc wire spray is excellent for its affordability and durability, as its bond strength is slightly better than that of combustion thermal spray coatings. A bond coat is normally necessary for an electric arc, with nickel aluminide being the most common bond coating choice.

Combustion Thermal Spray Coating

To apply combustion thermal spray coatings, molten metals like zinc and aluminum are sprayed onto the surface to create a basic coating. Materials on the wire are melted and broken down into atoms by compressed air to form a refined spray. Combustion thermal spray coatings can help prevent corrosion on your machines.

We look forward to helping you properly protect your machinery. Learn more about our various thermal spray coating services by getting in touch with our team today.