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Amid the roar of factory floors, within the steel and iron of urban infrastructure, and even on the delicate components of medical devices, thermal spray technology is playing a crucial role as an invisible guardian. This process, which transforms materials into specialized coatings, has long transcended the confines of the laboratory and has become a practical solution to addressing pain points across industries.


In the rolling mills of steel mills, the constant friction between hot steel plates and rollers once posed a headache for engineers. Traditional rollers often wore out within a few months, requiring costly replacements and disrupting production. Thermal spray technology has changed this situation. The ceramic alloy coating formed on the roller surface can withstand temperatures exceeding thousands of degrees Celsius while resisting the intense wear of the steel plates, extending the roller's service life several times. This significantly reduces downtime in the workshop due to equipment downtime, reducing the maintenance workload for workers.


Underground water pipes in cities have also benefited from this technology. In the past, long-term exposure to water and impurities caused corrosion and scaling on the inner walls of pipes, which not only affected water delivery efficiency but also created the risk of leaks. Thermal spraying creates a corrosion-resistant and wear-resistant coating on the inner walls of pipes, like a sturdy "protective coat," effectively preventing direct contact between water and the pipe itself. After years of operation, the pipelines remain unobstructed, significantly reducing the frequency of excavation and maintenance, and ensuring a stable and reliable urban water supply.


In the medical field, the application of thermal spraying technology embodies its unique combination of precision and user-friendliness. The surface treatment of artificial joints demands extremely high biocompatibility, requiring them to be compatible with human tissue while also possessing sufficient wear resistance to withstand daily activities. Hydroxyapatite coatings created using thermal spraying technology, with a composition similar to the inorganic components of human bone, promote the growth of bone cells on the surface of artificial joints, achieving "osseointegration." This not only strengthens the implant but also reduces the impact of wear debris on the body, significantly improving patients' quality of life.


From large-scale equipment in heavy industry to medical devices critical to life and health, thermal spray technology, with its unique "coating magic," solves practical problems in diverse scenarios. As the technology continues to advance, we believe it will create unexpected application value in even more fields, continuously bringing convenience and breakthroughs to our daily lives.

Corrosion never sleeps. It is the moisture, salt and chemicals that constantly attack metal surfaces whether it is a steel bridge, an offshore platform or factory equipment. Painting has long been the most popular form of protection but is it the most effective over the long run?



This article breaks down how painting stacks up against thermal spray coating and why more industries are choosing thermal spray as the stronger, longer-lasting defense against corrosion. Read on to learn more.

Why Corrosion Protection Matters
Industries are spending billions of dollars annually because of repairs or downtimes and lost productivity through corrosion. Just think rust is a mute robber; it deteriorates your property even when you are not even in sight. When the surface coating decays, it is just a matter of time before the decay extends. The right protection choice can be the solution between five years of repair and a 30year solution.

Understanding the Basics
Let us clear up the fundamentals before comparison.


Painting is done with liquid coatings that are allowed to form a thin layer covering the metal surfaces to protect against oxygen and moisture.
Thermal spray coating involves the heat to melt either metal or ceramic material and sprayed on the surface at high velocity. The result? A coating that is thick and tough. It bonds tightly and lasts much longer.

For a quick overview of processes and materials, see our Thermal Spraying Guide.



How Each Method Works:
Painting forms a chemical shield between the metal and the environment. Gradually, this layer breaks and sheds its skin or becomes lightened by sun and changes in temperature and abrasion. When that occurs, the corrosion may begin beneath the paint.



Thermal spray coating forms a physical, mechanical bond. It does not simply cover the metal but it becomes a part of it. Metals such as zinc and aluminum or stainless steel are sprayed on to form a dense shell over the surface. This ensures that it is ideal in severe environments such as marine docks or pipelines and chemical plants.





The Big Comparison: Thermal Spray Coating vs Painting
Here’s a clear side-by-side look at how these two stack up.








Feature



Thermal Spray Coating



Painting





Service Life





15–30+ years (material and environment dependent)



3–10 years before recoating





Bond Strength



Mechanical (sometimes metallurgical)



Chemical bond only





Thickness



150–500+ μm



50–300 μm







Temperature Resistance



Up to ~1000 °C+ (material dependent)



Limited by resin (often < 200 °C)





Damage Tolerance



Local repairs hold well



Damage often spreads under film





Environmental Resistance



Excellent in salt, chemicals, and heat



Better for mild/moderate exposure





Cost Over Time



Higher upfront, lower lifecycle cost





Lower upfront, frequent repaints





Best Use



Bridges, offshore, pipelines, power plants



Indoor or decorative applications








Explore our full range of Thermal Spray coating products designed for different industrial needs.



Which One Saves You More in the Long Run?
It is tempting to use paint as it is less expensive in the short run but that is short-term thinking. Painted surfaces require sandblasting or surface preparation and several layers of repainting every few years. Those labor and material expenses accumulate fast.



Thermal spray coating can be more expensive in the short run though it can last three to five times longer. Thermal spray is an easy winner when you sum up the entire lifecycle cost: maintenance or labor and downtime. That is to say, you spend a single time and have decades of peace of mind.





Real-World Example
Imagine you manage a steel bridge near the coast. A painted surface might hold up for five years before rust starts showing through. You’d need to shut down lanes, scrape, and repaint again and again.



Now imagine that same bridge coated with thermal spray coating. Zinc or aluminum layers act as a sacrificial shield, preventing rust even in salty air. It is possible to have that bridge last 25 years or longer with the proper sealing. This is the type of reliability infrastructure owners would love to have.



Why Industries Are Switching to the Thermal Spray
More companies are choosing thermal spray because they want results that last, not band-aid fixes. It’s become a favorite in:




Oil and Gas: Offshore drainage rigs, platforms and pipelines subjected to salt water.
Energy and Power plants: Boilers, turbo and stacks that are subject to intense heat.
Water and Wastewater Facilities: Machines that are in constant contact with water and chemicals.
Transportation: Bridges, railways and heavy duty vehicles that require long durability.

Each of these industries faces punishing conditions where paint simply can’t keep up.



Advantages of Thermal Spray Coating
Let’s sum up why thermal spray stands out:




Longer protection: One coating can outlast multiple paint cycles.
Improved adhesion: The particles of the melt fasten on the surface.
Individual materials: Zinc, ceramic, and carbide may then be utilized respectively to make corrosion-resistant, heat-resistant or wear-resistant layers.
Green: No volatile organic compounds (VOCs) and smelly solvents.
Quick repair: The damaged areas can be repaired without the removal of the whole coating.

No wonder engineers call it the “industrial armor” for metal surfaces.






The Lifecycle Advantage
Consider it as follows: painting is comparable to purchasing an inexpensive umbrella, it will work temporarily, though you will continue to buy other umbrellas. Thermal spray coating can be compared to the high qualitative raincoat, which can serve several years long.



In the case of large-scale assets, it is not only convenient but profitable to reduce downtimes and maintenance. That’s why smart asset managers are switching to thermal spray. They’re not chasing the cheapest fix; they’re choosing the solution that saves money over time.



Conclusion:
As far as corrosion protection is concerned, there is no doubt about the winner. Thermal spray coating is more cost-effective, has better adhesion, and durability compared to painting. It is not the most cost efficient in the short run, but it is certainly the smartest decision in the long term.



If you are sick of repainting or fixing and delaying; it's time to switch strategies. Find a permanent solution and not a retouch. It is time to select the protection that is really durable.



CY Thermal Spray Coating has been assisting industries all over the world in preventing corrosion for more than 40 years. Our custom coating also ensures that your equipment will be stronger, longer and prepared to face the most difficult conditions. Reach out today to find the best coating plan for your project because your assets deserve the strongest defense.



FAQs
Question 1. Is thermal spray coating better than painting for corrosion protection?

Answer: Yes. Thermal spray coating is much more durable and it is able to operate in rough conditions where paint would crack or peel. It forms a strong mechanical bond and offers up to five times more service life.



Question 2. Can thermal spray coating be applied over old paint?

Answer: It is better to take the old paint off. The surface must be smooth and coarse to be adhered to. Before spraying, the technicians of CY can assist with the preparation and evaluation of the surface.



Question 3. How long does thermal spray coating last compared to paint?

Answer: Compared to paint that can last 3-10 years, thermal spray coating has the potential to last up to 20-30 years without having to be repaired thus making it the wiser long run decision.