Spray and Fuse

Spray and Fuse: Elevate Corrosion Protection to New Heights.

Experience the ultimate in surface protection with Spray and Fuse Thermal Spray technique. This process combines the power of thermal spray technology with a fusion process, creating a robust and durable coating that adheres seamlessly to various surfaces. Say goodbye to corrosion, wear, and heat damage – Spray and Fuse Thermal Spray delivers unmatched performance and longevity.

What is Spray and Fuse?

Spray and Fuse thermal spray is an surface coating process that offers exceptional protection and performance for a wide range of industrial applications. This technique combines the benefits of thermal spraying with the superior bonding capabilities of a post-spray fusion process, resulting in a highly durable and reliable coating.

The Spray and Fuse method begins with the deposition of a powdered coating material onto the substrate using a thermal spray gun (Combustion Powder of HVOF typically). The gun propels the powder at high velocity onto the surface, where it forms a dense and adherent layer. This initial coating provides excellent adhesion and coverage.

Following the thermal spraying phase, the coated substrate undergoes a controlled heating process known as fusion. The heat is carefully applied to the surface with a Vacuum Heat Treatment or an acetylene heat gun, causing the coating particles to melt and fuse together. This fusion step enhances the coating's density, integrity, and mechanical properties, ensuring exceptional bond strength and resistance to wear and corrosion.

The resulting coating exhibits excellent resistance to abrasion, erosion, and chemical attack, making it ideal for demanding environments such as power generation and oil and gas. Additionally, the Spray and Fuse technique can be used to repair damaged or worn components, extending their service life and reducing downtime.

In summary, Spray and Fuse thermal spray technique offers a highly effective solution for achieving superior surface protection and enhanced performance. With its combination of thermal spraying and fusion, it provides durable, customized coatings that meet the stringent requirements of modern industries.

Spray and Fuse coating is used in:

Advantages of Spray and Fuse

Spray and Fuse thermal spray technique offers several advantages over other conventional thermal spray techniques, making it a preferred choice for various industrial applications. Here are some key advantages:

  1. Enhanced Bond Strength: The fusion process in Spray and Fuse technique significantly improves the bond strength between the coating and the substrate. The melted particles fuse together, creating a metallurgical bond that enhances adhesion and minimizes the risk of coating delamination or spalling.
  2. Superior Coating Integrity: The fusion step in Spray and Fuse ensures that the coating material is fully melted and fused, resulting in a dense and homogeneous coating structure. This leads to improved coating integrity, reducing the chances of porosity or voids in the coating.
  3. Enhanced Wear and Corrosion Resistance: The dense and fully fused coatings produced by Spray and Fuse exhibit excellent resistance to wear, erosion, and corrosion. This makes them highly effective in protecting surfaces subjected to harsh operating conditions, extending the lifespan of components and reducing maintenance costs.


  • Corrosion resistant
  • Oxidation resistant
  • Wear resistant

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Spray and Fuse F.A.Q.

The Spray and Fuse Thermal Spray technique offers several advantages. Enhanced Coating Durability: The fusion process in Spray and Fuse creates a metallurgically bonded coating with improved density and mechanical properties. This results in excellent resistance to wear, corrosion, extending the lifespan of the critical components

While the Spray and Fuse Thermal Spray technique offers numerous benefits, there are a few limitations to consider:

1. Process Complexity: The Spray and Fuse technique involves multiple steps, including thermal spraying and fusion. Achieving optimal coating quality requires careful control of parameters such as heat application and material selection, making the process more complex and time-consuming.

2. Substrate Limitations: The suitability of the Spray and Fuse technique depends on the nature of the substrate. Certain materials or surface conditions may not be compatible with the fusion process (~1000C), limiting its applicability in specific cases.