How thick are typical coatings deposited by thermal spray processes?

The coatings thickness is dictated by the size of the feedstock for powders, the size of the droplets for arc spraying or the size of the atomized droplets created by the liquid spray process. Typically, flattening of the material by factor of three of the particle size can be expected. To create thin coatings one requires a very fine particle size, usually at sizes between 10 and 20 microns. It is not uncommon to find coatings as thin as 30 microns. Liquid spray processing is able to decrease the thickness even more. Softer metals can typically be applied very thick. In some cases as thick as ¼”.