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Thermal Spray Coatings

What is the Thermal Spray Method? (Metallization, Metal coating)

Metallization, or Metal Coating, refers to the thermal spraying method. Metallic thermal spraying is among the technologies that transform solid materials (powder, wire, rod, drug core) into a high-energy material stream (combustible gas or plasma stream) to melt material partly or totally. This process helps disperse the material into particles in the form of fine mist, increasing the particle speed and pushing the particles to the prepared surface for coating.

Thermal Spray Coating Services provided by VIVABLAST

(Thermal Spray Aluminium, Thermal Spray Aluminium coating, Metallization)

We deliver high-quality metal coating/ metallization services such as Thermally Sprayed Aluminum (TSA)/ Zinc (TSZ)/ other metal alloys per NORSOK M-501.

We provide outstanding corrosion protection improvements over conventional coatings systems. We also perform well in protecting assets in marine and other industries from extreme temperatures and corrosive environments.

Thermally sprayed coatings are a cost-effective and straightforward solution that adds superior properties and performance qualities to engineered surfaces. The variety of substrates probably enhanced by thermal spray is virtually limitless.


Features of the thermal spray aluminum coating method

Metallization spraying possesses the following common characteristics:

  • Wide range of applications: Corrosion resistance, wear resistance, increasing the heat resistance of the metal.
  • Applicable materials: Metal, aluminum, zinc, alloy with speed up to 36kg/h.
  • Coating thickness: From 50 micron to 12mm.
  • Probability of thermal deformation: Minimal to none.
  • Effectiveness: Protect major components, and withstand heavy-duty applications for the strong adhesive force.

Thermal Spray Coating

What advantages does thermal spraying have over other coating technologies?

Thermal Spray Coating technology: (Thermal spray aluminum, thermal spray aluminum coating…)

  • Save materials and create layers of coating materials to the required thickness, suitable for new fabrication and restoration of used parts
  • Cover complex-shaped objects
  • Prolong the lifetime of metal by increasing the heat resistance, wear resistance, and corrosion resistance.
  • Enhance electrical conductivity
  • Reduce shutdown period, cut off the operating and maintenance cost
  • Reduce the cost of auxiliary parts.


  • Flare booms
  • Gas cylinders
  • All steel substrates
  • Assets operating between – 45oC to 538oC.

Application of metal coating method to reduce corrosion in insulation

In which cases is Thermal Spray Coating used?

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Here are some suggestions from VIVABLAST:

  • The surface required high precision, no thermal deformation, and no residual stress (can not do in case of welding)
  • Non-metallic materials surface with high-hardness
  • The surface required to cover with a high-thickness layer of metal like electroplating

How are Thermal Spray Coatings classified?

Thermal Spray Coatings (Metal Coating) are categorized as follows:

1. By temperature:

  • Warm Spraying (the  temperature of the engineered surface during spraying >250oC)
  • Cold Spraying (the  temperature of the engineered surface during spraying <250oC)

2. By spray material:

  • Powder Spraying
  • Wire Spraying

3. By spraying method:

  • Flame Spraying
  • Arc Spraying
  • Plasma spraying
  • High-velocity oxy-fuel coating spraying (HVOF)


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