Thermal Spray technologies allows for a material (Typically Metal) to be adhered to a base

material. This process allows for the use expensive/high performance metal alloys to be applied to lower cost base materials for improved performance at the location needed.

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Application Example 1:

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The Problem: To save on cost, pump manufacturers make rotary shafts from materials which experience wear and material degradation over time. This wear issue could be avoided by using  a very hard (and expensive) base metal, however the use of the material is cost prohibitive as the pump shafts are typically large parts. 

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The Solution: A properly designed and applied thermal spray coating allows for the base material to be comprised of a lower cost (lower performance) material and coated by a metal with superior performance (Corrosive properties, wear resistance, hardness ect...) at the location where the improved material performance is needed. This additive process allows for the final product to be made from a lower performance/cost material with the added performance at the location where it is needed. As a result, a large pump shaft can be manufactured from a low grade stainless or carbon steel and have a thermal spray coating such as a Nickel Super-alloy (Hasteloy C-276...etc) applied to the shaft at the wear/load points. 

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Application Example 2:

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The Problem: Waste water treatment plants use centrifugal pumps to move waste water. Particle contaminate (pebbles, snails,..etc) get into the flow and erode the vanes and housings of the centrifugal pumps, reducing efficiency. Given the typical size of these pumps, manufacturing these components from wear resistant base metals is cost prohibitive.

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The Solution: As an alternative to the base material of the vane and housing being made from an exotic material, a thermal spray coating can be applied to the exposed surfaces to prevent the continued erosion of metal and reduction in performance of the pump, thus increasing the efficiency and service interval of the pump.