Combustion spraying melts and atomises coating material using a gas flame to produce coatings that are wear and corrosion resistant.
Provides a cost effective method of applying metallic and ceramic coatings with clearance control and thermal barrier properties.
Can be used to restore worn components and apply anti-corrosion and anti-wear coatings with moderate bond strength.
What we do
Combustion spraying
Combustion spraying (sometimes referred to as Flame 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.
Benefits of Combustion spraying
Combustion spray coatings offer the following benefits:
- Corrosion protection
- Wear resistance
- Clearance control – abrasives and abradables
- Heat and oxidation resistance
- Temperature management
- Electrical resistivity and conductivity
- Manual thermal spraying is ideal when:
- Component geometry or working environment requires flexible access
- Large and complex areas (e.g., structural components) need coverage
- Flame spraying meets the required coating performance
- A cost-effective solution is preferred
Application & materials
Typical applications include:
- Pump shafts/journals
- Seal areas
- Impellors
- Housings
- Structures
- Components
- Metallics, ceramics, abradables
Aluminium, zinc, stainless steel, bronze, low carbon steel, nickel-based materials, molybdenum.
Combustion spraying process details
Combustion spraying is a thermal spray process that offers a cost-effective method for applying metallic and ceramic coatings in less demanding environments. It utilizes the heat generated from the chemical reaction between a fuel gas—typically acetylene or propane—and oxygen to melt the coating material. When balanced correctly, this reaction produces a gas stream exceeding 3,000°C.
In this process, a consumable material—usually in the form of a powder or wire—is heated and propelled onto a substrate to form a surface coating. The result is a versatile and efficient solution for enhancing surface properties such as wear resistance, corrosion protection, and thermal insulation.
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