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Plasma Spray

plasma spray

What is plasma spray?

Plasma spray is a high heat thermal spray system that combines technical aspects of both flame and arc spray. Plasma spray systems were the first systems capable of creating a high enough flame temperature to reliably apply carbide coatings. This high heat is the main benefit of plasma spray and allows for the application of ceramic coatings. Plasma spray uses an electrical arc to dissociate and ionize hydrogen and argon gases. The plasma spray gun injects powder into this spray stream to apply various types of coatings.

plasma spray gun diagram

Plasma Spray Solutions

Ceramic plasma spray coatings can be used as a thermal barrier for components used in high heat environments. Plasma coatings are also wear and corrosion resistant. Plasma thermal spray also offers I.D. spray capabilities.

Common Coating Solutions

  • Thermal barrier coatings
  • Abradable coatings
  • Cermets
  • Ceramic coatings
  • Nickel and Cobalt based coatings

Common Coating Materials

  • Chrome Oxide Ceramic
  • Aluminum Oxide Ceramic
  • T800
  • Chrome Carbide
  • Aluminum polyester abradables

Plasma Spray is great for...

  • High-temperature environments
  • Parts that experience a lot of wear
  • Corrosion resistance
  • Dielectric coatings

Plasma Spray Coating Properties

 Operating Cost


Bond Mechanism

Mechanical (<10,000 psi)

Max Flame Temperature

12,000-35,500° F

Particle Velocity

1,500-2,600 ft/sec

Max Spray Rate

18 lbs/hr

Coating Thickness Range

0.003" to 0.030"

Special Features

Capable of ceramic coating, no heat distortion

Wear Resistance


Corrosion Resistance

Very Good



Explore more...

Spray and Fuse
Arc Spray