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Thermal Spray Coatings



Thermal spray processes consist of the application of metal, ceramic or composites coatings (dispersions of ceramic phases in metal binders) onto metallic and non-metallic surfaces. Raw materials in wire, rod and powder (size 1 – 500 µm) form are heated to a molten or semi-molten state in a gaseous environment at high temperature and are accelerated towards the substrate, where they quickly solidify, creating an overlapping lamellar structure


Below there are different types of thermal spray coatings and some of their advantages.

Metal coatings such as Molybdenum, Aluminium alloys, Copper alloys, carbon and stainless steel, Nickel or Cobalt alloys (Colmonoy, Stellite, etc.) are deposited via Flame Spray (FS), High Velocity Oxygen Fuel (HVOF) and Air Plasma Spray (APS) technologies. These processes are performed in Zocca since 1967. Some metal coatings, if left rough without subsequent mechanical finishing processes (grinding, turning, etc.) have significant roughness, useful for carrying out the dragging of products.

Metal and metal alloys coatings PropertiesIndustries
Bronze, Aluminium, Nickel- graphiteAbradable coatingsAerospace
Cellulose & paper
Printing & graphics
Molybdenum – StelliteAnti-wear coatings
Carbon Steel, Stainless Steel, Aluminium, Bronze.Repair of worn surfaces and restoring of measurements under tolerance

Ceramic coatings are made of high purity metal oxide deposits and are applied through traditional or new Air Plasma Spray technique. They are chemically inert and have a high melting point. These characteristics give them resistance to aggressive or high temperature environments. Read More

Ceramic coatingsPropertiesProperties
Chromium oxide (Cr2O3)Anti-wear coatings, especially for sliding wear and for rotating gasketsAerospace
Cellulose & paper
Printing & graphics
Aluminium Oxide (Al2O3) pure or with added Titanium dioxide (Al2O3-TiO2)Anti-wear coatings, electric insulation also at high temperatures
YSZ (Yttria-Stabilized Zirconia ZrO3-Y2O3)Thermal barrier

Composite coatings (also called Cer-Met) consist of ceramic phases, typically carbides, dispersed in a metal matrix that acts as a binder. These coatings have a very high level of hardness, making them suitable for extreme anti-wear applications.

The presence, in some types of Cer-Met coatings, of metallic chromium, nickel- and cobalt-based alloys makes them suitable for use in aggressive environments, even at temperatures above 600°C.

The most widely used coating process for Cer-Mets is the HVOF due to the compactness, cohesion and adhesion that is achievable. For applications in which a high surface roughness is required, the Plasma Spray process is preferable. Read more.

Composites coatingsProperties Industries
Tungsten Carbide in Cobalt matrix (WC-Co);
Chromium carbide in Nickel-Chromium matrix (Cr3C2-NiCr);
Tungsten carbide in Cobalt-Chromium matrix (WC-Co-Cr);
Tungsten- and Chromium- carbides in Nickel matrix (WC- Cr3C2-Ni);
Anti-wear coatings
Coatings for aggressive environments
Coatings as alternatives to Chromium plating
Product gripping and dragging coatings
Oil & Gas
Cellulose & paper
Rubber and Plastic
Motor racing


Thermal spray technologies we provide: