HVOF Thermal Spray
HVOF is a high velocity, low temperature thermal spray coating process using gas combustion (hydrogen) or liquid fuel (kerosene).
Our Services
Plasma Thermal Spray
The plasma spraying process involves the latent heat of ionized inert gas (Plasma) being used to create the heat source.
Component Manufacturing
TSS offers the "value added" service of providing turnkey thermal spray coated components such as shafts or sleeves.
Repair & Dimensional Restoration
The equipment and parts in every industry are subjected to abrasive wear and/or corrosive and erosive wear.
Laboratory Services
TSS has a complete thermal spray metallurgical lab for coating development, application and process optimization to ensure quality results.
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Plasma, HVOF & Metallization Solutions for Industry
TSS s.r.l is unique in its ability to work with its customers and provide them with a custom engineered solution for their specific surface engineering requirements.
Due to our vast 30 years experience in the field of thermal spray coatings as well as the capabilities of our laboratory facilities, engineering department, and machining facilities, TSS s.r.l is highly capable of assisting you in any phase of thermal spray coatings.
What is HVOF coating?
High Velocity Oxy-Fuel (HVOF) coating is an advanced thermal spray process widely used to improve the performance and durability of critical industrial components. The system works by combusting fuel gases such as hydrogen or liquid fuels like kerosene, mixed with oxygen under carefully controlled pressure and combustion conditions. This reaction generates an extremely high-velocity gas stream capable of propelling coating particles at nearly supersonic speeds onto the substrate surface. The result is a dense, strongly bonded coating with superior hardness, wear resistance, and corrosion protection. In thermal spray technology, the rule is simple: higher combustion pressure means higher gas velocity, greater particle speed, and ultimately, better coating quality.
What is Plasma (APS) spraying?
Atmospheric Plasma Spraying (APS) is a thermal spray process that uses the energy of ionized inert gas — known as plasma — to generate an extremely high-temperature heat source. The most common plasma gas is argon, often combined with secondary gases to adjust the plasma characteristics. During the process, argon flows between the electrode and nozzle, where a high-frequency or high-voltage arc is established. This arc ionizes the gas stream, creating plasma. By increasing the arc current, the plasma arc becomes thicker and more highly ionized, producing the temperatures required to melt a wide range of coating materials.
What is thermal spraying?
Thermal spraying, also known as metal spraying, is an advanced surface engineering process used to enhance and protect critical components. In this technique, a wide variety of metals, alloys, and ceramics are melted and sprayed at high velocity onto the surface of another material, creating a strong and durable coating. The process is highly versatile and allows the application of protective coatings that improve wear resistance, reduce corrosion, restore damaged parts, and extend the service life of industrial equipment. Thanks to its adaptability, thermal spraying can be applied to different substrates—such as steel, aluminum, or composites—across industries like aerospace, automotive, energy, and manufacturing.
Chromium Carbide
Ceramic
Bronze Spray
Chromium Carbide
Thermal spray materials for Corrosion Resistance
One of the most effective solutions we provide is a coating blend composed of 75% chromium carbide and 25% nickel-chromium fine powders. Applied through the HVOF (High Velocity Oxy-Fuel) process, this material forms exceptionally hard, dense, and strongly bonded coatings.
Thanks to its unique combination of hardness, toughness, and chemical stability, HVOF chromium carbide coating offers outstanding protection against abrasion, fretting wear, and surface fatigue, even in highly corrosive or high-temperature conditions — typically between 540°C and 815°C (1000°F–1500°F).
These HVOF coatings exhibit extremely low porosity (less than 0.5% by volume) and remarkable adhesion strength, exceeding 12,000 psi (83 MPa). Their superior micro and macro hardness ensures exceptional wear resistance and long-term reliability for critical components operating under extreme thermal and mechanical stress.
By combining advanced thermal spray technology with precise material selection, TSS provides performance-driven surface protection solutions that extend component life and reduce maintenance downtime.
Ceramic
Plasma Tungsten Carbide: High-Performance Thermal Spray Material
We offer advanced thermal spray materials designed to deliver exceptional protection against wear, erosion, and abrasion. Among our most effective solutions is Plasma Tungsten Carbide, a fine-grade tungsten carbide–cobalt (WC–Co) aggregate powder engineered for the plasma spray process.
This high-quality coating material produces exceptionally dense and uniform layers, delivering superior low-temperature wear resistance compared to other tungsten carbide powders. Its robust composition ensures long-lasting protection against abrasive particles, hard surface contact, fretting, and particle erosion, making it ideal for critical components exposed to intense mechanical stress.
Through the precision of the plasma spray coating technique, Plasma Tungsten Carbide provides a smooth, hard, and adherent surface finish that enhances performance and extends the service life of machinery operating in demanding industrial environments.
With TSS’s expertise in thermal spray engineering, clients benefit from coatings that combine exceptional wear resistance with reliable performance — ensuring longer equipment lifespan and reduced maintenance costs.
Bronze Spray
Aluminium Bronze: Durable HVOF Coating for Wear and Restoration
Aluminium Bronze is a versatile and high-performance option for both surface restoration and wear protection. Produced from a fine-grade aluminium bronze powder, this material delivers dense, high bond strength coatings when applied through the HVOF (High Velocity Oxy-Fuel) process.
The resulting coatings are exceptionally hard, durable, and machinable, allowing for easy milling, drilling, tapping, and finishing. Thanks to its unique combination of physical properties, HVOF Aluminium Bronze is particularly suitable for the repair of worn or mis-machined non-ferrous components, as well as for soft bearing applications where fretting wear, cavitation, and surface fatigue are common challenges.
Compared with standard aluminium bronze deposits, HVOF-sprayed Aluminium Bronze coatings demonstrate superior hardness, improved tensile bond strength, and a smoother as-sprayed surface finish. These enhanced characteristics result from the HVOF process’s ability to produce high-density, low-porosity coatings with excellent adhesion and structural integrity.
By integrating Aluminium Bronze thermal spray coatings into critical components, industries can achieve longer service life, improved reliability, and reduced maintenance downtime — ensuring consistent performance even under demanding operational conditions.