Resources
Coating Guides
Straight answers on thermal spray coatings — how they work, how to choose, and how to stop components wearing out.
Corrosion-Resistant Coating for Steel: Choosing the Right OptionA corrosion-resistant coating for steel keeps moisture, salts, and process chemicals off the base metal using a thermal-sprayed metallic, ceramic, or carbide layer. This guide compares metalizing, sealed carbides, and ceramics, and lays out how to choose and budget for the right one.22 Jul 2026Wear-Resistant Coatings: How to Choose the Right Coating for Your Wear MechanismA wear-resistant coating is a thermal-sprayed metallic or ceramic layer that protects a component from abrasion, erosion, or sliding wear — but the correct material (tungsten carbide, chromium carbide, or ceramic) depends entirely on which wear mechanism is actually at work. This guide maps wear mechanism to coating material with a selection table and cost reasoning.20 Jul 2026Metalizing: Zinc and Aluminium Arc Spray for Long-Life Corrosion ProtectionMetalizing is the thermal spray process of applying zinc or aluminium coatings by arc spray to protect steel structures from corrosion for decades rather than years. This guide explains how thermal spray zinc (TSZ) and thermal spray aluminium (TSA) work, why they outlast paint, and where sealing and cathodic protection fit.17 Jul 2026What Is Plasma Spray Coating? The Ceramic Thermal Spray Process ExplainedPlasma spray coating uses a DC electric arc to ionize gas into a plasma jet exceeding 8,000°C, melting ceramics such as alumina, chrome oxide and zirconia that no combustion-based thermal spray process can touch. This guide explains how the process works, what materials and hardness it achieves, and where it fits against HVOF and D-Gun.15 Jul 2026What Is Stellite Coating? Cobalt-Based Wear and Galling ResistanceStellite coating deposits a cobalt-chromium-tungsten (Co-Cr-W) alloy onto a component surface, most often by plasma spray, flame spray or HVOF, to resist galling, corrosion and wear at temperatures where hardened steels and even tungsten carbide coatings lose their edge. This guide covers what Stellite is made of, how it's applied as a thermal spray coating, why it resists galling specifically, and where it fits against tungsten carbide and chromium carbide.13 Jul 2026Chromium Carbide Coating (Cr3C2-NiCr): High-Temperature Wear ProtectionChromium carbide coating (Cr3C2-NiCr) is a thermal spray coating built around chromium carbide particles in a nickel-chromium binder, applied by HVOF or D-Gun to protect components against wear at temperatures up to roughly 800-850°C — a range where tungsten carbide coatings oxidise and fail. This guide covers how it's applied, why it survives heat, where it's used, and how to specify it correctly.10 Jul 2026What Is HVOF Coating? The High-Velocity Oxygen Fuel Process ExplainedHVOF (High-Velocity Oxygen Fuel) is a thermal spray process that burns fuel and oxygen to accelerate coating powder to supersonic speed, producing dense, hard, low-porosity wear coatings such as tungsten carbide. This guide explains how the process works, what hardness and bond strength it achieves, and where it fits against plasma spray and D-Gun.8 Jul 2026D-Gun Coating: The Detonation Spray Process and Why It's DifferentThe D-Gun coating process fires repeated controlled detonations of fuel and oxygen to accelerate coating powder to the highest velocities in thermal spray, producing coatings with bond strength above 80 MPa and porosity below 1%. This guide explains how the detonation cycle works, why it outperforms HVOF on density and bond, and where D-Gun earns its higher cost.8 Jul 2026Tungsten Carbide vs Chromium Carbide: Choosing the Right CoatingTungsten carbide vs chromium carbide comes down to one decision rule: WC-CoCr delivers the highest wear resistance in the thermal spray family below approximately 450-500°C, while Cr3C2-NiCr holds its hardness and resists oxidation at temperatures up to roughly 850°C. This guide compares both coatings side by side and gives a clear checklist for specifying the right one.1 Jul 2026Tungsten Carbide Coating: Properties, Grades, and Industrial ApplicationsTungsten carbide (WC-CoCr) applied by HVOF or D-Gun is the highest-hardness coating in the thermal spray family, reaching approximately 1 400 HV with bond strength above 80 MPa and porosity below 1%. It is the industry-standard hard-chrome replacement on pump shafts, hydraulic rods, and other precision sliding-contact surfaces.29 Jun 2026Hard Chrome Replacement: Choosing a Coating That Performs BetterHVOF-sprayed WC-CoCr is the established hard chrome replacement for pump shafts, hydraulic rods, and industrial rolls — harder, denser, REACH-compliant, and free of hexavalent chromium. This guide covers replacement options, application fit, cost reasoning, and how to specify the switch.26 Jun 2026What Is Thermal Spray Coating? The Engineer's Complete GuideThermal spray coating is a family of five industrial processes that melt or soften feedstock materials and propel them at high velocity onto a prepared surface, building a dense, protective layer without altering the base metal. HVOF and D-Gun sit at the high-performance end; flame spray and arc spray handle large-area corrosion protection.25 Jun 2026HVOF vs Hard Chrome: A Side-by-Side Technical ComparisonHVOF-sprayed tungsten carbide (WC-CoCr) consistently outperforms hard chrome plating on hardness, porosity, hydrogen embrittlement risk, and REACH compliance — while matching or exceeding service life on hydraulic rods, pump shafts, and roll surfaces. This guide compares the two side by side and explains how to specify the switch.25 Jun 2026