Thermal Spray Powders (Spray & Fuse)

Dense & Durable, Metallurgically Bonded Coatings

For industries demanding high-strength wear protection, thermal spray & fused coatings offer a quick and cost-efficient solution that delivers dense, metallurgically bonded, low-porosity coatings with exceptional durability. Wall Colmonoy’s thermal spray powders are specially engineered for this application method – ensuring consistent flow, strong adhesion, and optimal fusing across a wide range of industrial parts and surfaces.

Ideal for parts exposed to abrasive wear, sliding contact, or corrosive environments, Spray & Fuse coatings are commonly used in the oil & gas, petroleum, chemical processing, power generation, waste-to-energy, automotive, rubber & plastic, agriculture, and glass container industries on various applications like pump sleeves, shafts, impellers, valve seats, mixing blades, extruders, neck rings, glass moulds, drill bits, stabilisers, steering pads, frack pump plungers/pistons, and many more.

Industries

Glass Container
Our advanced hardsurfacing alloys protect glass molds, plungers, and wear parts from extreme heat and abrasion, extending tool life and ensuring smooth bottle and jar production.
Oil & Gas
Drilling tools, pumps, and valve components in oil and gas operations benefit from our hardfacing alloys, which provide exceptional resistance to corrosion, pressure, and abrasive wear.
Pumps & Valves
From high-pressure chemical pumps to industrial flow valves, our advanced hardfacing alloys increase durability and prevent erosion in demanding fluid-handling applications.
Mining
Heavy-duty mining equipment - such as crushers, drill bits, and conveyor components - lasts longer with our wear-resistant alloys that combat impact, abrasion, and harsh conditions.
Rubber & Plastics
Our products protect extruder screws, molds, and processing dies in rubber and plastics manufacturing, minimizing friction-related wear and improving production efficiency.
Power Generation
Turbine blades, boiler components, and energy infrastructure benefit from our high-temperature resistant alloys, reducing oxidation, fatigue, and operational downtime.
Steel
From rolling mill guides to cutting tools, our hardfacing products help steel manufacturing equipment withstand extreme heat, pressure, and mechanical wear.
Automotive
Brake discs, engine components, and powertrain parts coated with our powders achieve superior wear resistance, improving performance and longevity in high-friction environments.
Agriculture
Our alloys extend the life of plowshares, harvester blades, and industrial mixers by protecting against abrasive soil, moisture, and heavy mechanical stress.

Products for Spray & Fuse Applications

Wall Colmonoy offers self-fluxing (containing Boron and Silicon) nickel- and cobalt-based powders formulated specifically for Spray & Fuse processes. These powders are designed to flow smoothly through our Spraywelder™ System and Fusewelder™ Torch to deliver strong, uniform coatings with excellent wear and corrosion resistance.

Whether you need general-purpose overlays or tailored solutions for extreme wear application and corrosive environments, our wear-resistant powders are available in a variety of particle sizes and chemistries to suit your application needs.

Find Your Powder

Technical Resources

Brochures and selector charts are available to the right. To search for a product, Safety Data Sheet or Case Studies, visit our Resource Library.

Resource Library
Surfacing Alloys Brochure

Explore our full portfolio of surfacing alloys designed to improve wear and corrosion resistance.

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TECH 1-K Selector Chart

Quickly compare alloy options to find the right fit for your thermal spray application.

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TECH-PTA/LASER Selector Chart

Review alloy recommendations and performance characteristics for PTA and laser cladding processes.

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TECH-HVOF Selector Chart

Identify the optimal powders for HVOF and HVAF spray applications with this quick-reference chart.

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Ready to extend the service life of your part? Contact us today to request a quote and find the right surfacing solution for your needs.

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