Thermal spraying is a group of processes in which freely divided metallic or nonmetallic surfacing materials are deposited in a molten or semi molten condition onto a prepared substrate to form a deposited coating. The thermal spray process normally is a cost-effective method for achieving equipment repair or improving new or used equipment performance. The process is an excellent repair method and should be considered, when appropriate, in lieu of other processes. Some of the potential problems of competing processes include the following: Welding existing components may cause unacceptable distortion, cracking, or heat treatment problems. Precise identification of the base metal is required for welding. Some alloys are difficult or impossible to weld. Welding frequently lowers the fatigue life of the component. Electroplating may be too slow or too limited in buildup capability, and it is environmentally hazardous.

This research project was produced for the National Shipbuilding Research Program as a cooperative cost-shared effort between the U.S. Navy and National Steel and Shipbuilding company (NASSCO).

"Research sponsored by the American Association of State Highway and Transportation Officials in cooperation with the Federal Highway Administration."