Atmospheric Plasma Spray

Atmospheric Plasma Spray

The atmospheric plasma spray process is used for wear and corrosion protection, thermal insulation, repair, and restoration. As it is the most flexible of all thermal spray processes coatings, can be applied onto all suitable base materials with the widest variety of powders.

Process description

A strong electric arc is generated between a positively charged pole (anode) and a negatively charged pole (cathode). This ionizes the flowing process gasses into the plasma state. We inject powdered feedstock material into the plasma jet, melting the powder particles and propelling them onto the workpiece surface.

Process basics

Heat source

Plasma Arc


Powder (Ceramics, Plastics, Metal)

Arc temperature

Approx. 16,000 °C

Particle velocity

Up to 450 m/s

Spray performance

4 – 8 kg/h

Schematic diagram of an atmospheric plasma process.

Key characteristics

  • Most flexible of all the thermal spray processes, with sufficient energy to melt any material
  • Excellent control of coating thickness and surface characteristics such as porosity and hardness

Typical applications

  • Combustion chambers
  • Blades and vanes
  • Hip ladles
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