Spray and Fuse Coatings

What is spray and fuse?

Spray and fuse uses high heat to increase the bond between the thermal spray coating and the substrate of the part. Unlike other types of thermal spray, spray and fuse creates a metallurgical bond between the coating and the surface. This means that instead of relying on friction for coating adhesion, it melds the surface and coating material into one material. Spray and fuse is the difference between adhesion and cohesion.

How Does Spray and Fuse Work?

Spray and fuses sprays a powdered material onto the component then follows with an acetylene torch. The torch melts the coating material and the top layer of the component material; fusing them together. Due to the high heat of spray and fuse, some heat distortion may occur, and care must be taken to determine if a component is a good candidate. These high temperatures are akin to those used in welding. The resulting metallurgical bond creates an extremely wear and abrasion resistant coating. Spray and fuse delivers the benefits of hardface welding with the ease of thermal spray.

spray and fuse

Spray and Fuse Solutions

The wear characteristics of spray and fuse can be closely compared to those of hardface weld overlaying. Metals used in hardfacing can also be used in spray and fuse; such as self-fluxing alloys. Like hardfacing, fusing creates low metal dilution but, unlike hardfacing, this can be true on coating thicknesses down to 0.030 inches. Low metal dilution means that the coating better maintains the wear and corrosion characteristics of the base metals during the spray process.

Spray and fuse is the most impact resistant coating at HTS Coatings. It is a corrosion resistant, highly abradable coating. Not every part will be a good candidate for spray and fuse due to the possible heat distortion. 

Spray and Fuse Sleeve Repair and Enhancement

Spray and Fuse Benefits

  • Metallurgically bonded coating
  • Hardface overlay alternative
  • Hardchrome plating alternative
  • Extreme wear resistance

Spray and Fuse Materials

Spray and fuse is great for...

  • High stress components
  • Augers
  • Exhaust fans
  • Sucker pump components
  • Pump pistons
  • Sleeves
  • Plungers
  • Ball Valves

Spray and Fuse Coating Properties

 Operating Cost


Bond Mechanism


Max Flame Temperature

1,900 to 2,050° F

Particle Velocity

160-300 ft/sec

Max Spray Rate

20 lbs/hr

Coating Thickness Range

0.030" to 0.060"

Special Features

Abrasion resistant, metallurgically bonded

Wear Resistance


Corrosion Resistance




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