The processes of thermal spraying are characterized by a powder or wire shaped material which is conveyed into an energy source.

As energy source a plasma, an electric arc (strictly physical also a plasma) or a fuel gas flame is used. These sources are generated by a torch or gun providing gases and/or electrical current. The fed material is molten or solidified. Following the kinetic energy of the gas flame or plasma accelerates the atomised particels in direction to the to be coated component. The particel velocity is depending on applied spray process and material. Due to the impact onto the component substrate and the relative movement between gun and workpiece a thermally sprayed coating is built up. The European standard EN 657 “Thermal Spraying” reveals an overview of terms and classification of the different spray processes¹.