5 Signs Your Equipment Needs a Coating Upgrade

Equipment failures are costly. Whether it’s unexpected downtime, high replacement costs, or inefficient operation, wear and corrosion can be the silent killers of industrial productivity. But before you replace worn components with standard OEM, it might be time to consider a coating upgrade.

At HTS Coatings, we specialize in thermal spray coatings that extend the life of equipment, reduce maintenance, and improve performance. If you're experiencing any of these five issues below, your equipment could benefit from a protective coating.

1. Excessive Wear is Leading to Frequent Part Replacements

If you find yourself replacing the same parts repeatedly, your components are likely wearing out faster than they should. Equipment in industries like mining, power generation, and manufacturing takes a beating from friction, heat, and chemical exposure. A wear-resistant coating—like tungsten carbide or ceramic—can add a protective layer that significantly extends the service life of critical components.

2. Corrosion is Causing Damage

Rust and corrosion don’t just make your equipment look bad—they eat away at the material, weakening structural integrity and leading to premature failure. If your components operate in moist or chemical-heavy environments, they may need a corrosion-resistant coating. Options like nickel alloys, stainless steel coatings, or specialized thermal sprays can create a protective barrier against corrosive elements.

3. Performance is Declining Due to Friction and Heat

Are your machines running hotter than they should? Are components failing under extreme temperatures or high-speed friction? Heat and friction reduce efficiency and increase energy consumption. Thermal spray coatings—such as ceramic or TBC (thermal barrier coatings)—can help protect base materials from heat, reduce friction, and improve overall performance in high-stress applications.

4. Unexpected Downtime is Impacting Production

Unplanned maintenance and emergency shutdowns can disrupt production schedules and drive up costs. If your equipment is constantly out of service due to wear-related failures, a preventative coating solution can help. Applying a coating before damage occurs can significantly reduce the need for urgent repairs, keeping your operations running smoothly.

5. OEM Parts Are Costing Too Much

If you're spending a fortune replacing parts straight from the manufacturer, there may be a better solution. Many worn components can be remanufactured with thermal spray coatings to restore them to like-new condition—at a fraction of the cost of buying new. Coating applications can help rebuild worn surfaces, improve durability, and reduce lead times, making it a cost-effective alternative to full replacement.

Don’t Wait Until It’s Too Late—Upgrade Your Coatings Now

If any of these issues sound familiar, a coating upgrade could save your company time and money while improving equipment performance. At HTS Coatings, we work with industries across the board to provide coatings solutions that tackle wear, corrosion, heat, and efficiency issues.

Ready to take the next step? Contact us today to learn how the right coating can extend the life of your equipment and boost your bottom line.