Thermal coating is a process which takes material in a wire form, heats it to the melting point, and then sprays it on a conditioned surface.  The molten material adheres instantly and provides a corrosion or wear resistant barrier which lasts for years.  There are several hundred different types of wire available for thermal coating, depending upon the application.  When corrosion resistance is required, we commonly use a zinc/aluminum wire that will provide protection in normal atmospheric conditions for twenty five plus years.  If material is subject to high wear, we utilize a very hard (55-60 RC), abrasion resistant coating.  Thermal coating can also be used to build up worn surfaces on parts such as rotating shafts and rolls.  Additionally, the process provides great galvanic protection for any part that will be encased in concrete.  We can even coat carbon steel parts with a stainless steel wire that will result in the same corrosion resistant properties as if the part were manufactured from stainless.

Zinc/Aluminum coating being applied to an adjustable pipe roller support.  The process looks hot, and it is when leaving the gun, but we have actually coated notebook paper!

Carbon steel support plate coated with a pure aluminum material.  This plate was installed, encased in a concrete wall, with the aluminum coating providing long lasting galvanic protection.

Carbon Steel Structural Support Plate that has been coated with the zinc aluminum wire. 

Carbon Steel Anchor that has been coated with zinc aluminum wire.

Hole auger cutting teeth thermal coated with a 55-60 Rockwell C hardness, abrasion resistant coating.  This same coating has been used on backhoe and bucket teeth, crusher parts, gravel chutes, and other high wear parts.