Plasma Powders & Systems Incorporated
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228 Boundary Road, PO Box 132
Marlboro, NJ 07746 

Phone 732-431-0992
Toll Free: 800-358-4287


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Frequently Asked Questions

Below are Plasma Powder's most frequently asked questions. If you have questions in which you cannot find the answer for here, please contact Plasma Powders to speak with one of our knowledgeable customer service representatives. Toll Free: 1-800-358-4287

 
 
 
 
 Frequently Asked Questions
  1. Who Are We? Plasma Powders & Systems, Inc.
  2. What is Thermal Spray?
  3. What can I coat with Thermal Spray?
  4. How does Thermal Spray differ from hot dip galvanizing?
  5. How is Thermal Spray used today?
  6. Is Thermal Spray environmentally friendly?
  7. What kind of Thermal Spray systems are available?
  8. What does it cost to get into this technology?
  9. Can the system be automated?
  10. What else do I need besides the system itself?
  11. What kind of materials are available?
  12. What are the manufacturers specifications associated with certain materials?
  13. What fuels are used?

Who Are We? Plasma Powders & Systems, Inc.

Plasma Powders & Systems, Inc. (PPS) has been supplying Thermal Spray material, equipment and training for over 35 years. PPS is a systems integrator. We offer equipment from several leading manufacturers which allows us to build complete and cost effective solutions for our clients. We manufacture wire and powders in addition to precision handling and automation equipment. Our technical staff has decades of field experience to get you the right answers fast and system purchases always entitle the buyer to FREE training in our Marlboro NJ facility.

Not sure if Thermal Spray is right for your application? Give us a call at (732) 431-0992 and talk to one of our technicians.

What is Thermal Spray?

Thermal Spray is an additive process in which melted (or heated) materials are sprayed onto a surface. These materials are typically pure metals or metal alloys in powder or wire form. In addition, ceramics and plastics can be sprayed.

What can I coat with Thermal Spray?

Generally, Thermal Spray systems can be used to coat any substrate that can withstand the impact of molten particles and absorb and dissipate the heat relevant to the application method used. Low melting point materials such as zinc can be sprayed onto paper, Styrofoam and similar materials. (Some systems transfer more heat than others, call for info).

How does Thermal Spray differ from hot dip galvanizing?

Thermal Spray zinc coatings provide long lasting (up to 40 years) protection in most galvanic conditions and the spray process is much cleaner with less environmental impact than chemical based hot dip galvanizing. Most Thermal Spray coatings can be applied in house, saving transfer and logistics costs.

How is Thermal Spray used today?

Thermal Spray is used mainly to rehabilitate or extend the working life of components, protect for wear, temperature or corrosion resistance, increase conductivity, enhance the appearance of architectural components and art objects, etc.

Is Thermal Spray environmentally friendly?

Thermal Spray is considered a “green” technology because:

  • It has widespread use in reconditioning items.
  • It has the ability to coat lighter, softer or more abundant substrates with hard, rare or expensive complex materials.
  • The vast majority of any process “waste” can be recovered/recycled.

What kind of Thermal Spray systems are available?

Below is a list and short description of commonly used Thermal Spray systems:

  • Combustion Wire - Oxy/Acetylene or Oxy/Propane fueled torch that uses wire form material.
  • Combustion Powder - Oxy/Acetylene or Oxy/Propane fueled torch that uses powder form material.
  • Electric Wire Arc - A dual wire system using electricity to melt wire form material.
  • HVOF - High Velocity Oxy Fuel delivers powder form material at supersonic speeds.
  • HVAF/HVOF - Hybrid Convertible HVAF-HVOF Thermal Spraying Equipment offers the highest spray rates in the industry in either mode.
  • Plasma – Multiple options. Extreme high heat spray system.

What does it cost to get into this technology?

Basic Thermal Spray systems are relatively low priced. Simple spray torches with gravity fed powder hoppers are a few hundred dollars. Any shop that is set up for welding is already equipped with many of the systems required for thermal spray.

Can the system be automated?

Yes, Plasma Powders & Systems, Inc. is a system integrator. We manufacture and distribute custom handling equipment and employ cutting edge robotics to create solutions to meet nearly any thermal spray need.

What else do I need besides the system itself?

Depending on the situation and equipment purchased, compressed air, fuel gas, dust collection and noise attenuation may be some of the costs to be considered. Part and/or spray handling and automation may also be worth looking into as they perform very well in production environments and typically pay for themselves in savings.

What kind of materials are available?

Powder and Wire are the most common. Powders are available in almost any alloy. Basic powders can be altered more easily than pre-alloyed drawn wire simply by changing the ingredients.

Wires can be solid, pure or pre-alloyed chemistry, powder cored (powder inside a hollow core) or solid cored (PPS Bondrite™ is a solid nickel core wire).

What are the manufacturers specifications associated with certain materials?

Some manufacturers specify exact chemistry, particle size, tolerance, production method and even equipment and atmospheric values for the powders used to coat their parts. These typically involve aerospace, military and other high end or critical parts. Spec materials often carry a much higher price than an equivalent material made with less stringent procedures and reporting requirements. For many thermal spray coatings, excess costs can be avoided with no impact to quality by using a “chemically equivalent” powder.

What fuels are used in thermal Spray?

Most combustion systems use either Oxy/Acetylene or Oxy/Propane. In some cases, Oxy/Natural gas can be used in place of Oxy/Propane.

 
 
Plasma Powders & Systems Inc.
Thermal Spray Company
228 Boundary Road,
PO Box 132
Marlboro, NJ 07746

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Phone: 732-431-0992
Toll Free: 800-358-4287

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