Metal/Thermal Spray was invented in the early 1900’s and since that time it has developed into a process that affects our everyday living beyond all recognition. The Metal Spray Process involves heating of the material to be applied and projecting it onto the substrate no solvents or chemicals are used and it involves minimum heat into the substrate.

The purpose of this article is to provide sufficient insight to the value of the process of metal spray, how it has changed the way we live and how we are surrounded by a form of technology that a lot of people still don’t know exists.

The process has been used in every conceivable industry including Aerospace, Automotive, Biomedical, Agriculture, Space travel, Power Generation, Construction, Mining and so on. The metal/thermal spray process is a coating procedure used to change the surface properties of a part by adding a layer(s) of material to increase many factors:-

• Durability
• Hardness
• Wear resistance
• Increase or decrease in friction
• Increase of corrosion protection
• Change electrical properties
• Replacing worn or damaged material

The materials use in this coating procedure can be:-
• Metallic
• Ceramic
• Cermets
• Plastic

Substrate materials include:-
• Metals
• Glass
• Carbon fibre
• Plastics
• Plaster
• Polystyrene
• Ceramics
• Wood


Where did Metal Spray originate?


Dr Max Ulrich Schoop pioneered metal spraying in the early 1900’s when he discovered molten lead and zinc would stick to almost any surface. It was after this that the first method of thermal spray was invented – Flame Wire Spray.


This photograph is iconic through the Metal Spray Industry as the Birth of Metal Spray