5 Advantages Of Thermal Spray Coating For Weld Cladding

Thermal spray coating is a process of applying molten metal deposits. This is ideal for weld cladding because it provides a smooth and even surface. It can also be used to repair castings or other industrial components. In this article, we’ll discuss the benefits of thermal spray coating for weld cladding and show you how it works!

Low Cost and High Performance Weld Cladding

The thermal spray process is a cost-saving advantage because it can be applied at lower temperatures than other methods, which means less energy is used.

And since the materials used are inexpensive, the cost is further reduced by using more. This means that you get more bang for your buck!

There’s also a reduction in labor costs because thermal spraying doesn’t require a large investment in tools or equipment.

Longer Tool Life Enables Multi-Cavity Tooling

Another advantage of thermal spray coating for weld cladding is that it can be used to increase the life of your tools. The longer tool life means better production rates, enabling multi-cavity tools. In other words, you can produce more parts per hour with a multi-cavity tool when using thermal spray coating versus a single cavity tool. This increases your capacity and reduces the cost per part by facilitating higher volume manufacturing processes that capitalize on economies of scale.

Avoidance Of Cast Defects while Weld Cladding

One of the biggest problems with casting is that it can be difficult to control for defects and voids. This is especially true when working with lower-quality materials that are not suited to casting or may have been damaged during processing. For this reason, thermal spray coating provides an excellent alternative method for creating castings without having to worry about these issues.

Thermal spray coating works by spraying a fine powder onto a surface via a process called pyrolysis (heating at high temperatures). Once applied, it dries and hardens almost instantly into a durable shell around the coated object, making it ideal for repairing defects and improving the quality of existing parts.

Protection From Corrosion, Oxidation And Erosion

Thermal spray coating provides protection from corrosion, oxidation and erosion. This can reduce the cost of maintenance, replacement, and downtime. Applying thermal spray coatings to parts in a factory or on-site can save on costs by reducing your need for regular repairs or replacement. In addition to this, it will help you avoid the potential downtime that may be caused by equipment failure due to damage from exposure to water or other elements.

Overcoming The Limitations Of Casting Geometry

Casting geometry is limited to a single cavity, so the geometry of the part must be designed to fit into that cavity. Thermal spray coating allows you to coat multiple areas of your part in multiple layers.

Thermal spray coatings can be applied on either side of a cast part, making it possible for you to apply coatings inside or outside the casting, or both! This provides an added level of protection for your product if it needs extra strength in certain areas. It also simultaneously enables thermal spraying on top and bottom surfaces (or both sides).


We have seen some benefits thermal spray coating can provide to your welding process. The most important thing is understanding what you are trying to accomplish and determining which processes will work best for your situation. It may be worth considering when deciding between thermal spray coatings or another method, such as shot peening or electrochemical passivation because many factors come into play when choosing which one is right for you.

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