Plasma Spray coating

The versatility of plasma coatings allows for almost unlimited applications.

Plasma Coating Technology

Plasma coatings can be applied in four different ways.

  • Thermal spray application

  • Arc spray application

  • Plasma application

  • HVOF application.

These work by using either combustion of gas and oxygen or an electrical arc process.

Performance Properties

  • Chemical and thermal resistance
  • Optimum permeation resistance
  • Flame resistance
  • Hard finish resistant to abrasion
  • Purity

With plasma coatings a wide variety of metallic and ceramic materials can be heated and sprayed onto a surface to change the properties of the component, for example an aluminium roll can be coated in tungsten carbide to increase its surface hardness. Within this process surface preparation is critical, by sandblasting each individual part we are able to ensure a clean and well etched surface for plasma coatings to adhere to.

The versatility of plasma coatings allows for almost unlimited applications however they are commonly used within oil and gas, aerospace, automotive, printing, converting, paper and packaging industries.

Surfaces that plasma coatings can be applied to

Metallic substrates

Stainless Steel
Steel Alloys
Carbon Steel

Metallic substrates

Carbon Fibre
Glass Fibre

Thermal Spray

Thermal spraying uses the combustion of gas with oxygen to melt the coating material which is then propelled onto the surface to form. In most cases we are able to apply another polymer over the top of a thermal coating which, for example, enables us to provide a non-stick but high traction finish. As thermal applications are porous they allow polymers to impregnate the coating. Aluminium, Tungsten Carbide and Chrome Oxide can be applied using this process.


The Plasma coating process uses inert gas and charges it with electricity causing an arc flame which burns at temperatures of around 16000°c. Metallic or ceramic powder is then injected into the flame and sprayed onto the surface which forms a dense finish creating corrosion resistance and abrasion resistance.

Arc Spray

The arc spray process electrically charges two metallic wires with opposing polarity and forces them together causing wire to get extremely hot and melt. Compressed air is then used to atomise and accelerate the molten material onto the surface. By altering the wire feed speed and amps we can achieve a variety of surface roughness’s and thicknesses.  Aluminium (known as Thermally Sprayed Aluminium or TSA), Nickel alloys and Zinc (known as Thermally Sprayed Zinc or TSZ) can be applied using this process.

HVOF (High Velocity Oxy Fuel)

The HVOF process uses a combination of oxygen and gas mixed and then ignited in a combustion chamber to produce a high pressure gas stream. This stream of gas is used to carry metallic and ceramic powders at supersonic speed, melting the material and causing it to hit the surface at high velocity. This produces a dense finish which can be easily ground and polished to a high specification.


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