How Thermal Spraying is Used in the Aerospace Industry

Metallisation | 11th December 2020

Flame Spray

Flame Spray

Over the years, the aerospace industry has become best known for using advanced technology to create innovative aircrafts used all over the world for various functions. However, it is also vital that these creations are adequately taken care of and are well-maintained. One of the solutions to this problem is thermal spraying.

What Is Thermal Spraying?

Thermal spraying is the act of coating a surface, in this case, an aircraft, with metals, plastics, and alloys that have been heated. The materials are heated at too high temperatures and then sprayed onto the desired object at an extreme velocity to release millions of droplets.

Thermal spray coating is best used for maintenance as it prevents natural occurrences like rusting, corrosion, and general wear and tear. As there is an increasingly high market demand in the aerospace industry, thermal spraying has quickly become necessary for manufacturers.

Thermal Spray Coating Techniques

Many companies within the industry offer a wide range of thermal spray coating techniques. Here are some of the major ones that most offer:

Plasma Spray Coating

Plasma spray coating is best used for parts that are susceptible to extreme heat, like aircraft turbine engines. It ensures that these parts are well-maintained and safe to use.

This technique helps these turbines hold out against extreme heat and the force required to enable an aircraft to take off. That's because, during take-off, there is an immense amount of pressure on the plane's engines. When you use the aircraft over an extended period, it could affect its performance and become potentially dangerous.

What plasma spray coating does is to ensure the engine is more durable, more resistant to harsh conditions, and has a much longer life span by creating a heat barrier and making it more corrosion resistant.

Flame Spray Coating

Flame spray coating is a type of thermal spraying technique that uses both combustions from fuel emissions with oxygen to melt a material designed for spray coating, which is then applied to an aircraft's body.

It is a more cost-effective method of spray coating and a much more environmentally friendly option than the other available techniques. Aside from its more affordable pricing, it is also a better option for more extensive and complicated structures.

Flame spray coating is an excellent technique to use if you want to prevent corrosion and revitalize worn-out shafts and other gears.

High-Velocity Oxygen Fuel (HVOF) Spray Coating

This technique is similar to the flame spray technique in that it also involves combining oxygen and fuel to create a hot gas. This gas is then used to melt and speed up the powder material onto your desired aircraft surface.

This option is one of the most popular choices within the aerospace industry. They are most often used to withstand severe conditions like abrasions, corrosive conditions, and heated environmental temperatures.

The Final Finish

Thermal spraying is used within a wide range of industries including the aerospace industry and the construction industry and provides all these industries with a number of unique benefits. Since 1922, Metallisation has been the UK’s leading developer, manufacturer and worldwide supplier of a full range of thermal spraying equipment and consumables.

Interested in finding out more about how thermal spraying is used within the aerospace; or how it can be used within your own industry? Get in touch and speak to a member of the Metallisation team today on 01384 252 464 or send us an email on You can also contact a member of our team by using the contact form below.

Thermal Spraying

Thermal Spraying