Thermal spraying is a process whereby heated metal powder is applied by spraying within the desired applications. You could also call it metal spraying. It is used for pump and motor components, shafts, bearings, seals, machine and tool parts, measuring tools, measuring fixtures, valves, pistons, guideways, wearing bands, etc. There are countless possibilities.
The lifetime of the workpieces and applications is extended up to 8-9 times, due to the very high carbide content in the coatings. Tungsten carbide has a hardness of 2200 HV5. Typical particles that cause wear such as quartz or sand have a hardness of around 1200-1500 HV5. By comparison, the hardness achieved using various heat treatments (hardening) is typically 700-800 HV5. Thermal spraying thus offers much higher wear resistance.
In addition to much longer lifetimes, advantages of the process include a very low friction coefficient, good wear characteristics and good corrosion resistance. In most cases, it is a much better solution to purchase a cheaper material and apply a thin coating, than to purchase more expensive tool steel and then heat treat it. Not only in relation to costs, but also resistance to wear.