The Flame (or Combustion) Powder Spray process uses a similar technique as the Flame Wire Spray process, except that the wire feedstock is replaced with a powder. The main advantage of this process is that a much wider range of materials (such as nickel or cobalt-based self-fluxing alloys or ceramic materials) can be easily processed into powder form giving a larger choice of coatings. Many alloys are difficult or cannot be produced in a wire form and for this reason, it was developed.

The process relies on the chemical reaction between oxygen and fuel of combustion to produce a heat source. This heat source creates a gas stream with a temperature in excess of 3,000°C with correctly balanced conditions between oxygen and acetylene. The feedstock material to be sprayed is fed into the flame in the form of a powder to melt and the thermal expansion of the combustion is then used to atomize and accelerate the particles onto the substrate.

Typical coatings cold gas spray graphic

• Self-fluxing alloys (fusing)
• Iron-based alloys
• Nickel-based alloys
• Ceramics & Cermets
• Abradables

Main applications

• Wear resistance
• Corrosion protection
• Chemical resistance
• Dimensional restoration