HVOF Thermal Spray Coating: Step-by-Step Process, Advantages & Industry Applications

In industries where components face extreme wear, heat, and corrosion, a reliable protective coating is critical. High Velocity Oxygen Fuel (HVOF) coating also called HVOF thermal spray has become one of the most effective solutions.

This blog explains everything you need to know about HVOF: 

• What it is and how it works 

• Step-by-step coating process 

• Benefits and limitations 

• Materials commonly used 

• Applications across industries 

• Comparison with other thermal spray methods 

By the end, you’ll know exactly why HVOF coating is trusted in aerospace, oil & gas, power, automotive, and beyond. 

What is HVOF Coating? 

HVOF (High Velocity Oxygen Fuel) coating is a type of thermal spray process. It works by igniting a mixture of fuel gas and oxygen inside a combustion chamber, producing a high-pressure, high-speed flame jet. 

Fine powder coating material  such as tungsten carbide, chromium carbide, or metal alloys is injected into this jet. Particles are heated and accelerated to near-supersonic speeds (≈800–1000 m/s) before striking the component surface. 

On impact, the molten/semi-molten particles flatten, bond tightly, and form a dense, hard coating layer with very low porosity (<1–2%). 

The HVOF Coating Process – Step by Step 

1. Surface Preparation 
   • Grit blasting or cleaning ensures proper surface roughness. 
   • Removes contaminants for strong adhesion.
2. Combustion Setup
   • Fuel (hydrogen, kerosene, propane, or natural gas) is mixed with oxygen. 
   • Combustion creates a high-pressure jet flame.
3. Powder Injection
   • Coating material powder is fed into the jet. 
   • Particles accelerate to near-supersonic speeds. 
    
4. Deposition on Surface
   • Heated particles strike the substrate, flatten, and solidify. 
   • Builds a dense, high-strength coating layer. 
    
5. Finishing
   • Coating is polished, ground, or machined for smoothness. 
   • Final thickness typically 50 microns – 1 mm.

Advantages of HVOF Thermal Spray Coating 

• Exceptional hardness & wear resistance 

• Very low porosity (<1–2%), ensuring strong barrier protection 

• Excellent adhesion strength (bond strength often >80 MPa) 

• Corrosion resistance in marine, chemical, and oil & gas settings 

• Oxidation resistance at high operating temperatures 

• Extended component lifespan → reduces replacement costs 

• Versatile: works on carbides, alloys, metals, and composites  

With the rise of advanced HVOF coatings & services, industries now rely on these solutions not just for durability, but also for meeting strict quality and performance standards.

Common Materials Used in HVOF Coating 

Applications of HVOF Coating 

HVOF coatings are used wherever durability, precision, and reliability are non-negotiable: 

• Aerospace & Aviation – turbine blades, landing gear, compressor shafts 

• Oil & Gas – valves, drill tools, pump parts exposed to wear/corrosion 

• Power Generation – gas & steam turbines, boiler tubes 

• Automotive & Engineering – pistons, gears, hydraulic rods 

• Marine Industry – ship propellers, marine shafts, pump components 

• Paper & Printing Industry – rolls, cylinders, print heads 

Industries often choose thermal spray coating services when they need both precision and long-term reliability. 

HVOF vs Other Thermal Spray Methods 

Limitations of HVOF Coating 

• High equipment and operating cost 

• Skilled operators required 

• Not ideal for coating small, thin, or heat-sensitive parts 

Future of HVOF Coatings 

• Growing use in renewable energy, EVs, aerospace, and defense 

• Development of nano-structured powders for even higher performance 

• Increasing demand for eco-friendly alternatives to hard chrome plating 

Buyer’s Checklist Before Choosing HVOF Coating 

•  Does the component face abrasion, corrosion, or high-heat environments 

• Is component replacement more expensive than coating? 

• What base material and coating thickness is required? 

• Which coating material (WC-Co, CrC-NiCr, etc.) best suits your application? 
•  Can you work with a certified HVOF provider for quality control?

Why Choose EWSLLP for HVOF Coating? 

When it comes to precision thermal spray solutions, expertise matters. At EWSLLP, we combine advanced equipment, certified processes, and industry experience to deliver hvof coatings & services that meet the highest global standards. 

• State-of-the-art HVOF coating process facility 

• Expertise in tungsten carbide, chromium carbide, and alloy coatings 

• Proven track record in aerospace, oil & gas, power, and automotive sectors 

• Customized solutions to match your component needs 

•  Focus on quality, durability, and cost efficiency 

Whether you need to extend the life of turbine blades, protect pump shafts, or enhance the performance of critical parts EWSLLP is your trusted partner in HVOF thermal spray coating. 

Get in touch with our experts today to discuss your coating requirements.

Conclusion 

High Velocity Oxygen Fuel (HVOF) coating is one of the most advanced thermal spray technologies. By combining extreme hardness, corrosion resistance, and excellent adhesion, it ensures critical components last longer, perform better, and reduce lifecycle costs.