The Plasma Spray process is a high frequency arc that is ignited between an anode (nozzle) and cathode (electrode). The process gases flowing between them are ionized to become a plume of hot plasma spray (12,000°F to 30,000°F).  When the coating material is passed through the gas plume, it is melted and propelled towards the substrate as a thermal spray forming the plasma coating.

Since the flow of each of the gases and the applied current can be accurately regulated, repeatable and predictable plasma coating results can be obtained.

The distance of the plasma gun from the substrate keeps the part at a controlled thermal spray temperature that is usually in the range of (100°F to 500°F).


  • Large choice of industrial coating materials, including metals alloys, ceramics, cermets, carbides and others.
  • Thermal plasma spraying produces surfaces for a wide variety of applications, including resistance to many different types or wear and corrosion mechanisms, desirable thermal or electrical characteristics, and surface restoration and dimensional control.
  • Excellent control of coating thickness and surface characteristics, such as porosity and hardness.
  • Low heat affected zone or component distortion.
  • High deposition rate.
  • High bond strength of the coating to the substrate.
  • Coating of complex geometries.
  • Masking protection of areas that are not to be coated.
  • Process can be fully automated utilizing robotic equipment.
  • Coating of some internal bores possible.