Sprayed Coatings

Thermal Spray Coating Services

High Quality, Flexible Thermal Spray Coating Services

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Our Focus is on Quality & Flexibility

We stake our reputation on long-standing thermal spray coating expertise. Our customers turn to us as their strategic thermal spray partner because of our focus on flexibility and quality.

Flexibility

Flexibility is a key strength to look for in your thermal spray coatings partner. Hayden Corp. offers the flexibility to handle large parts or small, in high volume, small batches, or one-offs.


Our handling capacity — up to 6 tons, 72” diameter, and 400” length — is broad, as is our diverse material inventory of 300-plus active materials ready for thermal spray coating application. 


Whether your components require HP-HVOF, HVOF, Plasma Spray, Arc Wire, Flame Powder, or Flame Wire thermal spray coatings, we can handle it. Additionally, our multi-process cells for plasma, HVOF, and arc wire application allow us to complete this work consistently and repeatably in high volume. 



Quality

At Hayden Corp., quality is an intent built into the way we treat our customers and their components, from job start to finish. 


Customer service is part of that quality experience. We want you to turn to us as the experts when you have questions. Not sure which thermal spray coating application is best for your component and the wear problems it will experience? Our sales engineers will advise you. Need to meet strict military or commercial specifications? Our technicians are also certified for a variety of specialized applications for both military and commercial OEMs. 



Our Process

Hayden Corporation plans automation into nearly every job. Robotic application of thermal spray coatings minimizes human error and inconsistency, allowing us to approach each component with utmost flexibility, repeatability, and accuracy.


We strive to be a turnkey, high quality solution for our customers. Our on-site metallurgical lab team has a full complement of physical testing capabilities. We also complete in-house machining and finishing, including CNC grinding and superfinishing, reducing lead time and improving quality by eliminating outside subcontract operations.



Thermal Spray Coating Services

Thermal Spray Coating Information & Frequently Asked Questions

  • What is thermal spray used for?

    Thermal spray coatings are a versatile surface enhancement that are used in a variety of industries and applications to improve wear or corrosion resistance or restore dimension. Generally speaking, thermal spraying involves heating finely sprayed metal or ceramic feedstock and projecting it onto a substrate, where the coating material cools and densifies. These metal and ceramic coatings can be applied to a wide range of materials, including metal alloys, ceramics, and even plastic and composite materials. In addition, the thickness and composition of the sprayed layer can vary depending on the requirements of the application. Some common uses for thermal spraying include corrosion barrier coatings of aluminum on steel parts, hard tungsten carbide surfaces on high-wear machinery, and hard, corrosion resistant ceramic coatings on industrial pump and valve components. Furthermore, thermal spraying is a relatively cold process, when compared to welding, allowing coatings to be applied with minimal distortion to sensitive components.


  • What is the thermal spray process?

    Thermal spray is a process used to apply coatings, such as metals or ceramics, onto surfaces. This is done using an aerosol of molten particles or a high-velocity stream of solid materials, which are then projected onto the target surface through a combination of heat and pressure. Thermal spray coatings are mechanically adhered with the individual particles cooling and locking into the roughened surface to which they are applied.


  • What is the most commonly used form of thermal spraying?

    The most common type of thermal spraying is plasma spraying. In this process, an electric arc is used to heat a stream of inert gas to very high (plasma) temperatures, which then melts the particles of the coating material. This molten material is then sprayed at high speeds, where it rapidly cools and adheres to the target surface.


  • What are the different types of thermal spraying?

    There are many different types of thermal spraying, each of which uses different materials and techniques to create the desired results. Some of the most common forms of thermal spraying include plasma spray, high-velocity oxy-fuel spraying or HVOF, flame spray, arc wire spray and spray & fuse.


  • What type of materials are used in thermal spray coating?

    Most metals and ceramics and some plastics can be applied by thermal spraying. Common coating materials include metals such as stainless steel, titanium, cobalt and nickel superalloys, and various other pure metals and blends. Other thermal spray materials include ceramics, plastics, and composites. The composition of these coatings can be customized based on the needs of the application, and different materials can be combined at the time of spraying to create specific coating results.


  • What are the benefits of thermal spray coating?

    These coatings are highly durable, which makes them ideal for use in harsh or aggressive environments where traditional metal components would wear or corrode over time. They are also resistant to heat and corrosion, so they can withstand the stresses of high temperatures or chemical exposure without losing their protective properties. Additionally, these coatings can be customized to suit a range of different needs. Whether you need to protect an engine from wear and tear or a large industrial machine from corrosion, thermal spray coatings have the potential to provide outstanding results. So if you're looking for an effective way to improve the life of your mission critical machinery or other equipment, consider the economical addition of a thin and durable thermal spray coating.


Thermal Spray Coating Experts

With over 100 years of experience, Hayden Corp has established itself as an industry leader in thermal spray coatings and other cutting edge finishing technologies. With our advanced thermal spray coating systems and unparalleled expertise, we have become a go-to source for everything from thermal barrier coatings to corrosion protection. Whether you are looking for effective coating solutions for a new product line or need help maintaining your existing equipment over time, Hayden Corp has the experience, expertise, and resources needed to exceed your expectations.


Thermal Spray Coating Resources


arc spray coating
By Hayden Corp. 27 Jul, 2023
Arc spray has emerged as a reliable and versatile coating method, offering numerous advantages across various industries. With its enhanced coating durability, versatility in material selection, cost-effectiveness, surface restoration capabilities, improved performance, and environmental benefits, it has become a go-to choice for coating needs.
Exploring the Advantages and Applications of Thermal Spraying
By Hayden Corp. 27 Jul, 2023
Metallizing, also known as thermal spraying or metal spraying, is a surface coating process that involves the application of metallic materials onto a substrate. Learn more about common metallizing materials and benefits.
ceramic coatings applied using plasma spay thermal spray process
By Hayden Corp 01 Apr, 2023
Ceramic coatings have long been known for their durability, wear resistance, and high-temperature properties. When it comes to wear resistance, these coatings are particularly effective in applications where materials require high hardness, protection from erosion, or chemical resistance. In this article, we'll provide an overview of some of the most common types of ceramic coatings used for wear resistance in thermal spraying.
thermal spray coating for military and defense equipment
By Hayden Corp 06 Feb, 2023
Military hardware and vehicles need to be able to withstand the harshest environments. Thermal Spray Coatings ensure that these pieces of equipment are durable, reliable, and capable in extreme conditions - keeping our troops safe on operational missions.
Show More

Thermal Spray Coating Gallery

Thermal Spray Coating Quote

Searching for thermal spray companies near me?  Contact Hayden Corp Today!

Complete our online quote request form below.
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Thermal Spray Quote Request

Contact Hayden Corp.

Have a question or have a specific need?  Contact our main office or send us a message online. 

Call 413-734-4981 sales@haydencorp.com
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