System Comparisons
This is system comparisons of Thermal Spray Coating Systems. The systems that we will compare are  combustion wire, combustion powder, twin wire electric arc, HVOF, and plasma.
Each of the thermal spray processes have their specific area where they have the best properties for specific applications. It is best to evaluate the material properties required and the economics involved to be sure to select the correct process.
The chart below is brief overview of the different common thermal spray processes.
| System | Combustion Powder | Comustion Wire | Electric Arc | HVOF | Plasma |
|---|---|---|---|---|---|
| Energy Source | acetylene/oxygen | acetylene/oxygen | electric arc | propane-propylene/oxygen | plasma “flame” with argon-hydrogen-nitrogen |
| Material Best Sprayed | powder metals, alloys, fusible coatings | wire metals, alloys | wire metals, alloys | carbides, metals, alloys, fusible coatings | ceramics, bond coat |
| Secondary materials | ceramics, carbides | cored wires, cored with select powders like carbide | carbides, metals, alloys | ||
| Cost | less than $6,000 | less than $8,000 | less than $25,000 | less than $40,000 | less than $100,000 |
| Advantages | low cost, easy to use, wide material selection, low operating cost | low cost, easy to use, lower cost materials, low operating cost | easy to use, high spray rates, lowest operating cost | densest coatings, outstanding for carbides | highest energy “flame”, outstanding for ceramics |
| Disadvantage | powders generally cost more than wire, ceramics and carbides less dense than HVOF and plasma | limited to materials made in wire | high initial cost, limited to materials made in wire | high initial cost, high heat, higher training time, noise, high consumption of gases | highest initial cost, most complex process, long training time, noise |