Since it’s patented debut in 1882, thermal spraying has continued to grow and develop over the years. It’s gone from the some-what dangerous applications of the past and built into the portable and much safer applications of the here and now. 

Today, manufacturers are able to make use of multiple types of processes in which to coat their product. One such useful application is flame spray. Although more advanced processes have been developed, this particular process offers its own unique benefits and has continued to be a strong asset to manufacturers around the world.

Together, we’ll touch base on several aspects of this kind of thermal spraying technique so that you will learn if it is the right choice for you and your company.

A Rundown of Flame Spray

An Explanation

Using a mixture of combustion and oxygen to heat the material (either in powder, rod, or wire form), compressed air or inert gas is then shot through the molten material to propel it into a spray mist. This is used to coat the material over the chosen product.

The spray rate is moderate, and the coating left behind has a high amount of porosity, low bond strength, and a high oxide content.

Flame spray coatings are great for corrosion protection, as well as bearings. Due to the high porosity of the coating, lubricants can be used effectively and helps aid in the performance of the bearing.


Cost Effective

This process is great for products that will be fine with a slightly lower level of coverage than other processes. Often a product might not have a need for a demanding kind of coating and that is when flame spray comes into play. It gives you a good coating for a low cost.

The equipment itself is also cheaper than other spraying types. The materials used in the process, such as the power, wire, or rods, are cheaper than most others, bringing it on par with arc spraying costs. 

Flexible Coverage

Being able to adjust for any kind of shape makes this type of process is excellent, especially for manufacturers who work with items with complex geometric shapes. The manual spraying allows for you to get into all of the nooks and crannies, giving you complete coverage.

It does great when it comes to coating large areas as well.

Easy to Use

The design of the process makes it easy to learn. It won’t take much training or practice for an operator to learn how to use it effectively and safely.

Alternatively, you can also seek out professional coating services, such as Industrial Coat, to help you with all of your metal coating needs.


This spray machine is small enough that you are able to take it on the go without it being encumbering or difficult. This is great for jobs that take you outside of your regular workshop, or shops that might not have a large working area.

Safer for the Operator

Compared to other types of spraying processes, this flame spray process is lower in fume and dust levels. It can be done without a spray booth as long as you use proper extraction procedures. It also has lower noise levels than other spray techniques. With lower levels on all these accounts, it can be safer to operate with lower risks of inhalation or hearing damage.

Choose the Coating Best For Your Product

As you can see, flame spray coating will continue to be a viable and solid choice even after over 100 years in use. It’s a technique many manufacturers recommend. Despite the age of the process, it still outshines other spray processes in several ways.

Have any questions? We have answers.