Flame Spray

flame spray

What is flame spray?

Flame spray coating is the most basic form of thermal spray and one of the oldest. It's tried and true techniques provide great restoration for damaged machine parts. Flame spray at HTS Coatings is typically performed using oxygen and acetylene and can be sprayed with either wire or powder materials. Flame spray melts these materials in the combustion stream and applies the material to the part.

Flame Spray Process Diagram for Wire Materials

flame spray wire diagram

Flame Spray Process Diagram for Powder Materials

flame spray powder diagram

Flame Spray Solutions

Flame spray can easily repair surface erosion but is also good for larger surface gouges since it can deposit large amounts of material easily. The flame spray gun is designed to be sprayed robotically and can spray inner diameter (I.D.) and outer diameter (O.D.) surfaces. It can also be transported to a site for field service repairs of larger machine parts. Flame spray is the most economical solution if one is seeking wear resistant surface enhancement.

Common Coating Solutions

  • Abradable coatings
  • Metals
  • Alloys
  • Composites
  • Self-fluxing
  • Aluminum Oxides Cermets

Common Coating Materials

  • Stainless steel
  • Bronze
  • Babbitt
  • Nickel aluminum

Flame Spray is great for...

  • Shaft enhancement or repair
  • Bearing housing enhancement or repair
  • Casting repairs
  • Mold dye enhancement or repair

Flame Spray Coating Properties

 Operating Cost


Bond Mechanism

Mechanical (1,000-5,000 psi)

Max Flame Temperature

5,600° F

Particle Velocity

160-300 ft/sec

Max Spray Rate

20 lbs/hr

Coating Thickness Range

0.005" to 0.250"

Special Features

Economical, no heat distortion

Wear Resistance


Corrosion Resistance

Poor to Medium



Explore more...

Arc Spray
Thermal Spray