What Is The Difference Between HVOF And Plasma Spray Coating?

Industries with high operating needs must distinguish between HVOF (High-Velocity Oxygen Fuel) and plasma spray coatings. HVOF can create tight molecular bonds and handle abrasion stresses. Plasma spray can apply coatings at between 10,000 and 20,000 degrees Celsius.
Choosing between these two counts on the stresses your components will face. These might include abrasive wear in oil and gas or high temperatures in aircraft engines. HVOF coatings have a bond strength of over 80 MPa. Hence, weighing environmental conditions and component requirements will help you choose the coating that suits your durability and performance goals.
So, please continue reading to mug up each process and see how they differ.

What is HVOF?

HVOF deposits hard and wear-resistant coatings for components, including but not limited to aviation landing gear shafts and oil and gas ball valves. Burning oxygen and fuel to create a high-speed gas stream drives powdered materials toward the substrate for coatings with high binding strength and minimal porosity. It specializes in depositing carbide coatings, which withstand erosion and abrasion under severe conditions for better component life.
For example, HVOF-applied carbides protect the landing gear from the forces of takeoff and landing, and ball valves control resource flow. It attests to HVOF’s role in industrial component dependability.

What is Plasma Spray Coating?

Plasma spray coating is a flexible thermal coating technology for parts functioning at high temperatures. While melting and propelling coating material onto the substrate with a plasma jet through an electric arc, this process creates a heat barrier and improves corrosion resistance. It guarantees that energy, oil, gas, and manufacturing components can endure stern operations.
For example, it strengthens turbine blades for propulsion and flight for heat-resistant and dimensionally stable components. The fact that it can coat metals, ceramics, and cermets onto surfaces with multifaceted shapes shows its adaptability and efficacy in augmenting a key lifetime.

Key Differences Between Both Processes

1. Particle Velocity and Temperature

HVOF coating uses a combustion-driven high-speed gas stream to push particles. As a result, it creates thick, well-bonded, low-porosity coatings. HVOF particle velocities are 1000-1200 m/s, far more significant than plasma spray techniques’ 130-220 m/s. Also, plasma spray coating heats particles more than HVOF, which melts the materials with higher melting points.

2. Coating Material Options

Plasma spraying can treat metals, ceramics, and polymers due to its higher working temperatures, which render it appropriate for electrical insulation and thermal barrier applications. Because of its thick, robust coatings, metals and carbides utilize HVOF for better wear and corrosion resistance. Temperature and velocity affect which materials each approach can cover.

3. Coating Characteristics

HVOF coatings define high bond strength and density. The high kinetic energy of particles impacting the substrate creates coatings with minimal porosity and excellent adherence, surpassing 80 MPa. Given the dropped particle impact velocity and quick solidification, plasma-sprayed coatings may have increased porosity yet decreased adhesion (usually over 20 MPa). This coating difference makes HVOF better for applications needing better mechanical qualities and durability.

4. Surface Finish and Post-Treatment

Due to particle velocity, HVOF has a smoother finish and finer microstructure than plasma-sprayed coatings. Grind or polish HVOF coatings minimally to get the appropriate surface finish. Plasma-sprayed coatings may need extra surface finishing to smooth down their coarser roughness. It affects the final application when precise dimensions and surface smoothness are essential.

5. Application Environments and Costs

The application environment and cost also determine the decision between HVOF and plasma spray coating. HVOF is ideal for temperature-sensitive surfaces with thermal distortion because of its low operating temperatures and high particle velocity. However, fuel gasses and technology make it more costly. Plasma spraying, which can cover more materials, is cheaper than HVOF coatings for applications that don’t need exceptional durability and binding strength. So, selecting the correct coating technique for industrial applications involves weighing cost and performance.


In conclusion, when selecting between HVOF and plasma spray coatings, understanding the specific needs of your components is crucial. HVOF excels in providing robust, wear-resistant coatings with high bond strength, making it ideal for applications facing abrasive wear and demanding environments. On the other hand, plasma spray coating offers flexibility in material options and is suitable for parts operating at extreme temperatures. Consider factors such as particle velocity, coating characteristics, surface finish, and application costs to make an informed decision. Choosing the proper coating technique ensures durability and performance in industrial applications. So, analyze your requirements carefully and consult experts to make the best choice for your components’ longevity and efficiency.

Best Material Co., Ltd is an expert in producing plasma spray consumable parts like cathodes, anodes, and HVOF parts like barrels. If you need any of the parts, please contact us!

2024-04-04T13:16:01+00:00Uncategorized|0 Comments