Controlled Atmosphere Plasma Spray (ChamPro)

Controlled Atmosphere Plasma Spray (ChamPro)

Spraying in a controlled atmosphere produces a coating that is thin, dense, oxide-free, and very pure. Because of these properties, applications include land-based and in-flight turbine components and medical implants. Commonly used materials include metals, ceramics, and cermets.

Process description

Controlled atmosphere plasma spraying (ChamPro) refers to coatings applied in a chamber, usually at near vacuum. It applies superior coatings characterized by high densities or very controlled porosities with extremely low contamination. With this method, we can achieve certain results not possible with any other thermal spray process, such as thin layers, ceramic structures, and the application of refractory metals. 

Process basics

Heat source

Plasma Arc


Powder (Ceramics, Plastics, Metal)

Arc temperature

Approx. 16,000 °C

Particle velocity

200 – 400 m/s

Spray performance

35 – 100 g/min

Schematic diagram of a controlled atmosphere plasma process.

Key characteristics

  • Quickly produces thin, dense, full-coverage coatings
  • Capable of applying the full range of coating materials, including metals, ceramics, and cermets
  • Keeps the environment clean and safe as it’s a chambered process with full filtration package

Typical applications

  • Combustion chambers
  • Blades and vanes
  • Solid oxide fuel cells
  • Medical implants
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