In a world plagued by inefficiencies and dwindling natural resources, thermal spray technology may be the secret weapon to a more sustainable, scalable future. Thermal spray coatings are versatile and high performing, lending their capabilities to parts such as hydraulic cylinders, turbines, and print rollers. In fact, industries from mining to energy have embraced thermal spray technology in order to reduce resource consumption, increase efficiency, and extend component life. By opting to repair parts rather than replace, businesses can allocate their financial resources toward scaling instead of staving off equipment failure.

What is Thermal Spray Technology?

Thermal spray technology is an industrial coating process that heats or melts metallic or ceramic materials and deposits them onto a surface in order to improve its wear or corrosion resistance or repair it. Thermal spray coatings can be used on a wide range of parts but are usually selected for components or environments that must sustain heavy wear and corrosion. 

These coatings can be applied through a number of processes including:

• HVAF Spray

• HVOF Spray

• Spray & Fuse

• Plasma Spray

• Arc Spray

• Flame Spray

Typically, the chosen spray process will reflect the demands of the desired coating as well as the size and shape, substrate material, and the operating environment of the component. Each thermal spray process has unique benefits and limitations.

Sustainability Benefits of Thermal Spray Coatings

One significant benefit of thermal spray coatings is the management of both waste and pollution. These coatings help businesses across industries balance their environmental impact with economic growth.

Extending Component Life

When properly applied, thermal spray coatings produce a much better performing part, meaning component parts can withstand harsh environments and extensive wear. Parts coated with thermal spray coatings do not need to be replaced at such a high frequency, thereby lowering costs and producing less material waste. As a result, these coatings are a sustainable and environmentally friendly solution.

Increasing Material Efficiency

Picture two hydraulic cylinders: one with a thermal spray coating applied and the other not. Over the course of their service life, hydraulic cylinders are exposed to high impacts, pitting, and corrosion. Hydraulic cylinders can be coated with chrome plating, but thermal spray coatings can deliver 4x the wear life, protecting these parts where it matters most—on the surface. Thermal spray coatings can help manufacturers avoid the use of expensive or environmentally scarce materials such as superalloys. As a result, increased life translates to greater environmental sustainability and lower operating costs.

Energy Savings

Saving energy puts less stress on resources while protecting your bottom line. Traditional processes such as welding or casting can use up to 60 MJ/kg of energy. Metal casting, for example, is extremely energy intensive since you melt 100% of the material, even though only shape, not bonding, is required. While welding may only require moderate energy use, thermal spray technology still comes out on top as the most efficient, especially if you have stress-relieving requirements after weld. This is because thermal spray is surface selective and doesn’t add stress to the part. Plus, by using thermal spray, you avoid long furnace cycles, and there’s no bulk melting of the component. In the end, repairing a worn steel part with a thermal spray coating uses a fraction of the energy to make a new part. This makes it a great energy-efficient option. 

Developing a Circular Economy

A circular economy is an economic system specifically designed to eliminate waste and reuse rather than discard resources. This sustainable system adheres to the principles of reuse, repair, remanufacture, and recycle. Thermal spray coatings easily fit into a circular economy by making it possible to salvage and repair damaged, worn, or corroded parts. These restored parts are essentially “recycled,” eliminating the need to go out and purchase completely new components or machinery.

Reducing Use of Hazardous Chemicals

Traditional coating methods have often been called out for using hazardous materials, either due to potentially harmful chemicals or combustion byproducts. For example, chrome plating is one of the most regulated industrial surface treatments, yet it can still expose workers to hexavalent chromium. Even casting can create exposure to potentially toxic silica as well as molten metal fumes. In comparison, thermal spray coatings have a relatively low environmental risk profile since they do not use hexavalent chromium solutions, acids or cyanide baths, or bulk molten metal, and they do not contribute to wastewater streams.

Scaling Advantages of Thermal Spray Coatings

Scaling and sustainability may seem like an unlikely pair, but by leveraging thermal spray coatings, both can be achieved. Utilizing thermal spray coatings can actually facilitate the scaling process by giving manufacturers:

• Increased Versatility: Thermal spray coatings can be applied to parts ranging from pumps to vacuums and work well with a wide range of materials including ceramics, metals, and composites. Greater versatility allows businesses to scale and expand with increased ease.

• Enhanced Adaptability: Thermal spray coatings can easily be integrated with additive manufacturing and digital tools, like AI to increase the accuracy, precision, and efficiency of production.

• Higher-Performing Operations: High-demand industries, such as power and energy, require optimal performance. Applying thermal spray coatings to components such as turbines, pumps, and rotors promote higher-yielding and more efficient operations. 

For over a decade, HTS Coatings has championed the sustainable and scaling benefits of thermal spray technology. From cavitated pump parts to corroded rotor surfaces, we’ve seen firsthand how thermal spray coatings can boost performance and reduce environmental impact. Thermal spray coatings work hand in hand with your scaling goals, allowing you to limit energy consumption and the use of expensive material resources while enhancing the life, efficiency, and performance of your most valued parts.

Curious about thermal spray coatings? Reach out to HTS Coatings today to book a consult and discover how we combine sustainability and function for long-lasting results.

Resources:

• https://www.fst.nl/sustainability.html

• https://www.market-prospects.com/articles/manufacturing-s-next-revolution-how-thermal-spraying-solves-wear-corrosion

• https://woodrowscientific.com/blog?p=thermal-spray

• https://link.springer.com/article/10.1007/s42247-021-00307-1#:~:text=Thermal%20spraying%20is%20a%20scalable,CSAM)%20is%20already%20gaining%20popularity.