Our process portfolio includes plasma spray, HVOF, arc wire spray, and combustion-based deposition methods, allowing us to match coating materials and spray parameters to precise functional requirements.
Thermal spray is a family of deposition processes used to apply metallic, ceramic, carbide, cermet, and polymer coatings without altering the bulk properties of the substrate. Heated feedstock materials are accelerated toward a prepared surface, creating a bonded coating that delivers application-specific characteristics.
Process selection plays a critical role in coating performance, bond integrity, microstructure, porosity, and operating reliability. APS Materials offers a broad range of thermal spray technologies to accommodate diverse material systems and application requirements.
Flame wire spray utilizes a consumable wire feedstock melted within a combustion flame and deposited onto the substrate surface. The process is widely used for metallic coatings requiring efficient deposition rates and economical dimensional restoration.
Flame powder spray uses powdered metallic, ceramic, or cermet materials introduced into a combustion flame and deposited onto the substrate surface. The process accommodates a broad range of coating chemistries and functional surface requirements.
Twin-wire arc spray generates molten material through an electric arc formed between two conductive wires. Compressed air atomizes and propels the material onto the substrate, producing coatings well suited for corrosion protection, dimensional restoration, and large-area deposition.
High-Velocity Oxygen Fuel (HVOF) utilizes a high-energy combustion process to accelerate coating particles at extremely high velocities. The resulting coatings exhibit exceptional bond strength, low porosity, and dense microstructures, making HVOF a preferred process for wear, erosion, and corrosion-related applications.
Atmospheric Plasma Spray (APS) employs a plasma arc to generate temperatures capable of depositing materials with extremely high melting points. The process is commonly used for ceramic coatings, thermal barrier coatings, abradables, and specialized material systems requiring controlled microstructures.
LPPS and VPS are plasma spray processes performed in controlled low-pressure or vacuum environments. These technologies minimize oxidation during deposition and produce highly controlled coating microstructures for aerospace and other performance-driven applications.
Every process is run in a dedicated, monitored spray cell with controlled parameters and full traceability from setup through final inspection.
Discuss your project with our team to identify the thermal spray process, coating material, and deposition strategy best aligned with operating conditions, performance objectives, and manufacturing requirements.