Thermal Spray Coatings & Metal Repair Services
Extend the life of critical components with advanced thermal spray coating solutions. At IST, we restore, protect, and enhance metal surfaces using proven coating technologies designed for extreme industrial environments.
What Are Thermal Spray Coatings?
Thermal spray coatings are a process where metallic or non-metallic materials are applied in a molten or semi-molten state onto a prepared surface. This creates a durable, bonded coating that restores worn components, improves performance, and protects against wear, corrosion, and damage.
Originally developed in the early 1900s and widely adopted during WWII, thermal spray technology has evolved into a highly reliable and cost-effective solution used across industries worldwide.
Today, modern systems deliver consistent, high-quality coatings with exceptional bond strength and performance in even the most demanding applications.
Why Choose Thermal Spray Over Hard Chrome Plating?
Thermal spray coatings are increasingly replacing traditional hard chrome plating due to performance, environmental, and cost advantages.
Our Thermal Spray Coating Systems
IST utilizes multiple coating technologies to match the exact requirements of your component.
Twin Wire Arc Spray (Primary System)
The workhorse of industrial coating and repair.
- Bond strength exceeding 10,000 PSI
- Low application temperature (below 65°C) prevents distortion
- Large build-ups up to 0.250" per side
- Works on ferrous and non-ferrous metals
- Ideal for restoring worn shafts, housings, and bores
This process uses electrically melted alloy wire that is atomized and sprayed at high velocity onto the prepared surface, creating a strong mechanical bond.
Flame Spray
A specialized solution for:
- Hard-wear surfaces
- Manufactured components
- Liners and sleeves
What Can Be Repaired with Thermal Spray Coatings?
Virtually any worn metal component can be restored to original specifications or better.
Common Components
- Shafting (tail shafts, pump shafts, rudder stocks)
- Bearing fits and housings
- Pump sleeves and internal bores
- Drive components
- Seal liners and sleeves
Repairs can be performed on components ranging from small precision parts to large industrial shafts over 18 inches in diameter.
Materials We Work With
- Steel and stainless steel
- Cast iron and ductile iron
- Non-ferrous alloys
- Specialty alloys
With access to over 100+ coating alloys, we match the coating to your exact application requirements.
Industries We Serve
Thermal spray coatings are trusted across a wide range of industries:
Marine & Ship Repair
Mining & Heavy Equipment
Pulp & Paper Mills
Oil & Gas
Hydro & Renewable Energy
Aerospace
In fact, a significant portion of global thermal spray applications are used in aerospace, where reliability is critical.
Marine & Heavy Equipment Repair Specialists
IST has extensive experience in marine and heavy industrial repair, including work performed in shipyards and on critical vessel components.
Examples include:
- Tail shaft restoration
- Seal liner repairs
- Bearing housing rebuilds
- Large shaft machining and coating
Thermal spray allows components to be restored faster and at a fraction of the cost of replacement.