Who Are We? Plasma Powders &
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
Not sure if Thermal Spray is right
for your application? Give us a call
at (732) 431-0992 and talk to one of
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
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
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
Is Thermal Spray environmentally
Thermal Spray is considered a
“green” technology because:
It has widespread use in
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
What kind of Thermal Spray systems
Below is a list and short
description of commonly used Thermal
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
Electric Wire Arc - A dual wire
system using electricity to melt
wire form material.
HVOF - High Velocity Oxy Fuel
delivers powder form material at
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
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
What else do I need besides the
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
What kind of materials are
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
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
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”
What fuels are used in thermal
Most combustion systems use either
Oxy/Acetylene or Oxy/Propane. In
some cases, Oxy/Natural gas can be
used in place of Oxy/Propane.