Thermal Spray

Thermal Spray Powders for Functional & Protective Coatings

Thermal spray powder refers to metal, ceramic, or composite powders used in thermal spraying processes, where they are heated (via flame, plasma, arc, or HVOF) to a molten or semi-molten state and sprayed onto surfaces. The resulting coatings enhance durability, wear resistance, corrosion resistance, or thermal insulation of industrial components.

The quality of these powders is critical — they directly impact the coating’s performance, adhesion, and lifecycle.

Common Types of Thermal Spray Powders

1. Metal / Alloy Powders
Ni-, Co-, Fe-based alloys: NiCr, NiAl, CoCr, FeCrAl
Stainless steel: 304, 316, 420
Copper & aluminum alloys: CuSn, AlSi
▶ Applications: Corrosion prevention, electrical conductivity, and surface repair

2. Hard Alloys
WC-Co, WC-CoCr, Cr₃C₂-NiCr
▶ Applications: Erosion and wear-resistant coatings

3. Oxide Ceramics
Al₂O₃, Cr₂O₃, ZrO₂, TiO₂, Y₂O₃
▶ Applications: Insulation, thermal barrier coatings (e.g., YSZ)

4. Composite Powders
Al₂O₃-TiO₂, NiCr-Cr₃C₂ and more
▶ Applications: Multifunctional performance – wear, heat, corrosion resistance

5. Self-Fusing Alloys
Ni-, Co-, Fe-based self-fusing types
▶ Applications: Laser cladding or spray welding with post-fusion densification

Key Performance Requirements

• ✔️ Controlled particle size distributions (e.g. 15–45 μm, 45–105 μm)
• ✔️ High sphericity and flowability for efficient powder feeding and coating uniformity
• ✔️ High purity with minimal inclusions and low oxygen content
• ✔️ Homogeneous chemical composition for repeatable coating properties
• ✔️ Optional surface treatments: aerosolisation, inert gas spheroidisation, oxidation resistance

Application Areas

• Aerospace: Engine components, thermal barriers, oxidation-resistant coatings
• Energy & Power: Turbine blades, boiler tubes, corrosion-resistant parts
• Petrochemical: Anti-corrosion, anti-erosion coatings for chemical environments
• Automotive: Wear-resistant coatings for engine and drivetrain components
• General Machinery: Moulds, shafts, rollers requiring restoration or reinforcement
• Electronics: Ceramic insulation and heat-resistant functional coatings

Why Choose ULPMAT?

• ✅ High sphericity & excellent flowability – compatible with plasma, HVOF, flame, arc systems
• ✅ Tailored particle sizes for different thermal spray methods
• ✅ Diverse material range – from commercial grades to high-performance custom formulations
• ✅ Customised composition & distribution to meet special industry standards
• ✅ ISO-certified QC systems and expert technical support

📩 Need a reliable thermal spray powder supplier? Contact ULPMAT today to request samples or explore a custom solution for your coating challenges.