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Category Archives: Metal Spraying



What is Plasma Spraying?

Plasma spraying is a thermal coating process in which particles that have been softened by heat form a coating onto a substrate. This process aims to prevent corrosion or damage and allow materials that have been sprayed to last longer and have improved resistance. This popular form of thermal spraying can be used to coat any material and its flexibility can be used in many different industries such as medical, aerospace, automotive and agriculture.

How does Plasma Spraying work?

The coating material is in powder form and injected into a high temperature plasma jet which heats the powder before accelerating it out towards the substrate. The plasma gas acts as the spraying heat source and gets heated to such a high temperature that it ionizes and becomes electrically charged, meaning materials with high melting points can be sprayed.

The plasma gun itself comprises of a copper anode and tungsten cathode which the gas flows through and around, making plasma that is forced out through a constructing nozzle once mixed with the powder coating material. When combined, the powder becomes molten and fires out of the gun onto the substrate before cooling to form a coating.

What is Plasma Spraying used for?

Because plasma spraying is so versatile, it is one of the most popular thermal spray coating techniques available for producing high quality coatings that provide resistance, insulation, control, prevention and restoration, also you can find out how to get reliable but cheap truck repair. Plasma spray solutions may be necessary to protect industrial equipment and it is used across many different applications in industry sectors such engineering, electronics, chemical and nuclear, household appliances and more.

What are the advantages of Plasma Spraying?

Wide range of coating materials

There are a range of different materials that can be used as a quality coating using plasma spraying. Most materials are available in the suitable powder form such as metals, ceramics and alloys, and can be individually selected depending on the substrate. 

Wide range of substrate materials

Plasma spraying can coat many different substrate materials such as plastics, glass, metals and ceramics. 

Wide range of powder particle sizes

Compared to other types of thermal spraying, plasma spraying can use a wide range of powder particle sizes between 5-100µm. 

Maximise the lifespan of the substrate

Plasma spraying provides effective coatings that act as a protective barrier to a substrate, ensuring the material has a high resistance and is insulated and controlled.

What are the disadvantages of Plasma Spraying?

Equipment can be expensive

If you need to use plasma spraying, buying the specialist equipment can be expensive to buy and use/maintain.

Regular replacements

The internal components of the plasma gun can experience deterioration due to the high temperatures and they will need replacing fairly regularly to maintain the consistency of the coating. 

If you would like to find out more about plasma spraying or how we can provide quality coatings for you and your business operations visit and please don’t hesitate to get in touch. Here at IRS, we are fully committed to providing durability and high performance through our range of applications.

If you would like to find out more about plasma spraying or how we can provide quality coatings for you and your business operations, please don’t hesitate to get in touch. Here at IRS, we are fully committed to providing durability and high performance through our range of applications.


Published Date: 14th March 2019
Category: Metal Spraying



Impeller Repair Services

At IRS we  carry out lots of Impeller repairs like the examples in the images below. We can apply coatings to neck ring areas or weld up Impellers like the examples below. These pictures are before and after shots of the same Impeller.

Why not Let IRS have a look at your Impeller and with a little tender love and care, it can look as good as the one below.

Contact us online or call 01704 896332.

 Impeller-Repairs-1 Impeller-Repairs-2


Published Date: 14th February 2019
Category: Metal Spraying



What is Metal Spraying?

Metal spraying also know as Thermal Spraying involves covering a diverse range of surfaces with a metallic coating using a spray of molten particles.what-is-metal-spraying-image2

There are a whole host of metal spraying techniques including flame spraying, wire arc spraying, plasma spray, detonation spraying, high velocity oxy-fuel coating (HVOF), warm spraying, cold spraying, and high velocity air fuel.

The spraying technique that is right for you will depend on a number of different factors including the application you are using, as well as your budget, operational timeframe, and preferred finish.

We’ve created a helpful guide outlining everything that you need to know about metal spraying – we hope you find it helpful! 

How does Metal Spraying work?

Metal spraying is a process used across a vast range of different industries and involves using a high degree of heat in order to achieve a molten state.

Once the molten state is achieved, the material is then meticulously atomised into tiny particles, and then sprayed onto the surface you are working with. Once the particles hit the surface, they instantly even, flatten and harden to the surface forming a strong, durable and water resistant layer.

Although this technique is used across a number of different sectors, it is mostly associated with the anti-corrosion and engineering markets where precision, quality, fire prevention and protection and durability are essential.  With this in mind, you will quickly discover that this technique is used to add finishing coatings, create anti-corrosion layers and thermal barriers, as well as to optimise wear resistance.

The advantages of Metal Spraying

what-is-metal-spraying-image3Here’s a closer look at some more benefits that come hand in hand with metal spraying…

  • Increased durability
  • Modified electrical properties
  • Increased or decreased corrosion protection
  • Increased hardness
  • Increased or decreased friction
  • Increased wear resistance
  • Additional protection to damaged materials

But one of the main reasons why this technique is so popular and widely utilised is that the deposition rate of the surface is faster and easier than any other coating processes. 

IRS Thermal Spraying Systems & Processes

Detailed below are the Thermal Spraying systems and processes provided at IRS Surfacing Technologies.

HVOF Metallurgical & Ceramic Chemistries

For high quality repeatability coatings of low porosity and excellent bond strengths. Tungsten + Chrome carbides – full Ceramic ranges up to 1450 Hv. Chemical and, heat and wear resistant coatings of less than 0.5% porosity. Chemical resistant G30, C22, C276, Ultimet alloys and Titanium available.

High Energy Liquid Fuel – ABB 8 Axis Robotics & Integrated Turntable.

For highest quality, dense and high build deposits of soft alloy, anti corrosive and wear resistant materials. Tungsten Carbide ranges in excess of 1699Hv. Extremely low porosity deposits in excess of 3.0mm thickness. Inconel 625, Hastelloy C276, Ultimet and most corrosion resistant alloys. Soft aluminium bearing alloys, full Tungsten, Chrome and Titanium Carbide ranges in standard or proprietary matrices. Pure Titanium available. Proprietary analysis to meet special requirements. Incorporating fully co-ordinated 8 axis robotics and software support.

Plasma ARC (N.T.A.)

Full Ceramic wear resistant, chemical resistant & thermal barrier ranges including Chrome Oxide, Pure Alumina, Alumina Titania Dioxide & Zirconia Yttria. Tungsten & Chrome Carbide wear resistance.

Plasma Bore spray (NTA)

Above coatings to inside diameters and bores.

Plasma Arc (P.T.A.)

Hard, porosity free coatings molecular bonded. All alloys, Tungsten, Chrome, Titanium & Nickel Carbides. High Nickel Alloys & Bronzes etc. Stellite, Hastelloy, Inconel, Monel etc. Also, oscillator controlled spiral-welded deposits with low dilution levels.

Plasma Bore spray (PTA)

Above coatings to bores, barrels, feed lines & dies etc.

Plasma Bore spray (PTA)

Above coatings to bores, barrels, feed lines & dies etc.

Plasma Bore-spray (PTA)

Above coatings to bores, barrels, feed lines & dies etc.

Twin Reel Hypersonic Arc-Spray

Chrome alloys, Aluminium Magnesium, Bronzes, Stainless & Carbon Alloys, Hastelloy & Tungsten Carbides, also reclamation of component parts, bearing. journals & roller coatings etc. Offshore & chemical anti-corrosive coating. Chrome Alloy and pseudo metal coatings for Capstan Bull blocks & wire handling pulleys. Hastelloy C22 & G30 Alloys.


Full range of hard facing alloys plus mid ceramic facilities. Rocdur ranges in chordes. Nickel Alloys plus many more specific analysis.

High Velocity Arc-Spray

High Velocity Arc-spray deposits utilising high density higher bonded deposits in all consumables. Considerably better integrity and smaller particle structure than standard arc-spray deposits.

ArcSpray Bore-Spray

Full carbon steel, nickel and bronze alloy ranges.


Standard flame-spray facilities for fluxing alloys. Most mainstream Systems in operation.


Full range of fusion processes incorporating all leading manufacturers systems. Rebuilding press tooling and dies. Hard, dense virtually porosity free molecularly fused deposits where heat input to substrate is not a prohibitive problem.

Rokide/Norton Ceramics.

We are the only UK equipped & approved Rokide/Norton applications centre. The Rokide spray system is patented & unique in that it projects only fully molten particles on to the substrate as against plasma of flame-spray processes. Results are much improved anti-cavitation resistance particularly on point contact pressure applications such as wire drawing cones & assoc. wire drawing tooling.

Nylon & Plastics Spray

Anti-corrosion, chemical resistant and low friction coatings to pulleys, chutes and components needing to resist acid attack in low temperature non abrasive duties where a relatively cheap solution is required. Also good for decorative enhancement in most colours. Nylon 1 and EVA Plastic.

New! 80 Rc Tungsten Carbide on Tool Steel

Molecular bonded. Won’t chip or detach!!! Can be applied to injection moulding screws, rotary valve components & guillotine blades etc.


Why choose IRS Surfacing Technologies Ltd

IRS Surfacing are dedicated to providing a complete range of in-house thermal fringe technology that has been designed to accommodate the bespoke demands that come hand in hand with a wide range of specialist industries.

With over 20 years industry experience, we have continued to provide high quality, cost-effective solutions to premature and severe wear problems in the Aerospace, Off-shore, Chemical and Manufacturing Industries.

Above all, IRS really do have a ‘can do – can help’ attitude with both our much valued army of supporters and new clients alike.

If you have any questions about any of our services, please do not hesitate to get in touch or visit Our friendly and helpful team is always on hand to answer any of your questions, in order to ensure that you always find the right solution for your needs.

Please note: On site procedural and chemistry assistance and technical support is available without obligation.

For more detail regarding our Metal Spraying Service please Contact Us.


Published Date: 1st January 2019
Category: Metal Spraying, Thermal Spray Systems