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Combustion spraying

Benefits Application & materials Process details

Combustion spraying is a thermal spray coating process used to apply relatively inexpensive coatings that typically contain high levels of oxides and porosity together, with the option of achieving a rough surface finish.

In the combustion spraying process, a gas stream produced by the chemical reaction between oxygen and a combustion fuel heats a consumable propelling it onto a substrate to form a surface coating.

As the surface technology specialist in combustion spraying, Bodycote provides an array of spray coating materials to suit your specific needs. Backed by a customer-driven service, our facilities process a wide variety of component sizes to exacting standards with reliable, repeatable results.



Combustion spray coatings offer the following benefits:

  • Corrosion protection;
  • Wear resistance;
  • Clearance control – abrasives and abradables;
  • Heat and oxidation resistance;
  • Temperature management; and
  • Electrical resistivity and conductivity.

Application & materials

Typical applications include:

  • Pump shafts/journals
  • Seal areas
  • Impellors
  • Housings
  • Structures

Metallics, ceramics, abradables

Process details

Combustion spraying offers a cost effective alternative for applying metallic and ceramic coatings in a less demanding environment.

The process relies on the chemical reaction between oxygen and a fuel of combustion to produce a heat source. The heat source creates a gas stream with a temperature in excess of 3,000°C with correctly balanced conditions between oxygen and acetylene. A consumable, usually a powder or wire, is heated and propelled onto a substrate to form a surface coating.