Plasma Spray

Applying Ceramic Coatings Using Plasma Spray

Plasma spraying is a thermal spray process, in which metal or ceramic powders are injected into a plasma flame in order to protect industrial components from wear and corrosion.

The energy generated by the plasma gas–both thermal and kinetic–melts the powder particles and propels them at a high velocity onto the surface of any part requiring a protective coating. The particles impact the surface in a molten state, but rapidly cool to create a nearly impenetrable coating that adheres strongly to the part’s surface.

The plasma flame is capable of achieving temperatures well over 3,000 degrees Celsius, providing the high thermal energy needed to melt ceramic oxide powders, such as Zirconium Oxide and Chromium Oxide. No other thermal spray process has the capacity to produce enough thermal energy to melt ceramics.

Ceramic thermal sprayed coatings are used on an array of industrial products, including:

  • Jet engine components
  • Solid oxide fuel cells
  • Slurry mining valves
  • Surgical instruments
  • Molten metal processing equipment

Unidentified industries and potential benefits still exist, making the opportunities for plasma spray coatings endless.


Our CTS engineers are proud to be at the forefront of this technology, working with leaders, pioneers, and experts in the field to continuously identify new methods and develop new applications for our customer’s benefit.

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