Thermal Spray Coatings (HVAF / HVOF) Advanced Wear & Corrosion Protection for Critical Components

In harsh industrial environments, components exposed to abrasion, erosion, and corrosion often fail long before their expected service life. That’s where thermal spray coatings come in—providing a high-performance barrier that extends the life of your parts far beyond standard materials or traditional coatings.

We offer HVAF (High Velocity Air Fuel) and HVOF (High Velocity Oxy Fuel) thermal spray processes, applying dense, durable carbide and alloy coatings to protect critical surfaces. Whether you’re dealing with hydraulic rods, shafts, rollers, or oil & gas components, our coatings are engineered to handle the toughest conditions—reducing downtime and lowering replacement costs.

Common Applications

Hydraulic Cylinder Rods (for severe wear or corrosive environments)
Industrial Rollers (Bridle Rolls, Deflector Rolls, Sink Rolls)
Pump Shafts & Sleeves
Pins, Mandrels & Mechanical Drives
Oil & Gas Tools (Packers, Valve Stems, Plungers)

Coating Capabilities

Tungsten Carbide for extreme abrasion resistance
Chromium Carbide for high-temperature and corrosion resistance
Nickel-Based Alloys for chemical and erosion protection
Dense, low-porosity coatings with strong bond strength
Precise control over thickness, surface finish, and hardness

Choose High Tech Reman as your Thermal Spray partner

Customized Coating Solutions tailored to your operating environment
Complete in-house remanufacturing solutions with weld overlay
Ideal for components where replacement is costly or lead times are long
Integrated finishing with in-house grinding and polishing
Proven performance in heavy equipment components, steel mills, aluminum mills, oil & gas, and manufacturing sectors

HVAF / HVOF Thermal Spray FAQ Topics

What’s the difference between HVAF and HVOF?

Both HVAF (High-Velocity Air Fuel) and HVOF (High-Velocity Oxy-Fuel) are advanced thermal spray processes that apply dense, wear-resistant coatings. HVAF operates at a lower flame temperature and higher particle velocity, producing coatings with lower oxide content, less stress, and superior bond strength compared to traditional HVOF.

What materials do you typically spray (tungsten carbide, chrome carbide, etc.)?

We apply a full range of carbide and metal alloy coatings, including tungsten carbide, and chrome carbide, and multiple metal alloys. Each formula is tailored to resist specific wear mechanisms such as abrasion, erosion, and corrosion.

How do sprayed coatings compare to hard chrome in wear and corrosion resistance?

HVAF and HVOF coatings typically outperform hard chrome in wear and corrosion resistance. The coatings tend to be less ductile than hard chrome, and thus are not superior in all applications.

What surface preparation is required before spraying?

We perform precise grinding, surface grit blasting, and degreasing to achieve the correct anchor profile for coating adhesion. Surface preparation is critical, as even the best coating will fail without proper substrate cleaning and roughness control.

What bond strength is typical for thermal spray coatings?

Properly applied HVAF/HVOF coatings achieve bond strengths exceeding 10,000 psi, with excellent adhesion and minimal porosity (<1%). Our process ensures uniform thickness and strong metallurgical anchoring.

What are common failure causes (delamination, porosity) and how are they mitigated?

Common failures include spalling, delamination, and coating porosity, typically caused by improper prep or incorrect spray parameters. We prevent these issues through controlled spray temperature, standoff distance, and real-time monitoring of particle velocity and gas flow.

Can coatings be applied over weld overlays?

Yes. Our coatings are designed to bond perfectly over weld overlays and rebuild layers, creating a multi-layer engineered system that combines structural strength from the weld base with the extreme wear resistance of a carbide coating.

What finishes can be achieved after grinding or polishing?

After precision grinding and polishing, HVAF/HVOF coatings can achieve mirror-like finishes. We typically finish in the 4-12 Ra michroinch range, depending on applications.

Which industries and components benefit most from HVAF/HVOF coatings?

These coatings are used across mining, steel, aluminum, paper, and oil & gas industries on components such as hydraulic cylinder rods, pump shafts, rollers, pistons, and bearing journals — wherever long-term wear and corrosion protection is required.