Plasma Spray coating

The versatility of plasma coatings allows for almost unlimited applications.

Plasma Coating Technology

Plasma coating, sometimes known as thermal spray coating, is a coating application process where a metal or ceramic is sprayed onto a chosen substrate. The equipment used for the application is specialised and varies according to the desired outcome.

At Marcote our main focus is to apply the metals and ceramics to a porous layer. This porous layer is essential for top coating with a polymer or fluoropolymer, as it allows it to impregnate the metal or ceramic. This impregnation effectively creates a harder wearing topcoat.

By choosing the correct plasma layer and topcoat, Marcote can achieve properties such as high friction and non-stick, or abrasion resistance with low friction for example. An example of this would be an Aluminium roll coated in Tungsten Carbide to increase its surface hardness. The roughness or surface texture of the Tungsten Carbide can be varied. Note that when rolls are coated, we achieve very high levels of coating thickness accuracy, tolerance, and run out, which can be measured and recorded.

This ability to change the properties of the component being coated is the essence of what Marcote does.

As with all coatings, surface preparation is critical. We at Marcote use a high-grade silica to blast each individual part to a specified level of surface roughness and cleanliness. For those components that cannot be blasted, we employ various surface cleansing techniques. For more information on how we will handle and treat your components please contact us.

There are different methods of plasma or thermal spraying. The method used is dependent on the desired result. Their versatility allows for almost unlimited industrial use; for example, they are commonly used within oil and gas, aerospace, automotive, printing, converting, paper and packaging industries.


Performance Properties
  • Chemical and thermal resistance
  • Optimum permeation resistance
  • Flame resistance
  • Hard finish resistant to abrasion
  • Purity
  • Coating thickness between 80µm and 500µm

  • Surface roughness (Ra) of 1.5µm to 17.0µm plus

  • Hardness levels of between 28 HRc and 70 HRc

Surfaces that plasma coatings can be applied to

Metallic substrates

Stainless Steel
Steel Alloys
Carbon Steel

Metallic substrates

Carbon Fibre
Glass Fibre

Plasma Coating Application Types


In all cases and with all application methods, proper, thorough, and efficient extraction of excess coating is essential. Once extracted, filtration and capture of the waste product is carried out prior to responsible disposal. 

Marcote takes its environmental responsibilities seriously which is why we have invested in the latest generation of extraction equipment for our Plasma Coating processes.

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