Combustion Coatings (Flame Spray)

Combustion Coating (Flame Spray) is a very basic form of coating. A gun is simply fed with a wire, powder, or solid rod. The material is melted through combustion and the particles are fired from the gun towards the component to be sprayed. The particles hit the surface and form splats - a series of splats form a coating.

Common applications for combustion wire spray include basic wear coatings and corrosion resistant coatings (similar to twin wire arc). Ceramic rod can also be adapted for this style of coating as a basic thermal barrier coating.

The main advantage of the powder spray process over the similar combustion wire spray process is that a much wider range of materials can be easily processed into powder form giving a larger choice of coatings. Wear coatings and corrosion resistant coatings are still the most common types used.

Strategic Masking to Ensure Precision Combustion Coatings - PTFE Group produces tapes, fabrics, and compounds that are engineered to withstand the forces of Combustion Coating methods. All have exceptional resistance to high temperatures and abrasion. They are also highly conformable, have excellent adhesion and can be removed cleanly and easily to save time and added expense.

Key Considerations: 

  • Ensure that the temperature of the substrate and the time that the flame is trained on the masked surfaces (dwell time) does not exceed the limits of the masking materials.
  • Does the current process use multiple layers of tape? If so, a single, stronger layer of PTFE Group tape can be used instead.

Recommended Materials

For strategic masking prior to combustion coating process, we recommend the following materials: