Thermal spray coating involves heating a material, supplied in powder or wire form to a molten or semi-state. The material is atomized using a stream of process gases to deposit on various substrates, creating coating with thickness between a few micrometers to millimeters.

Upon impact, they form platelets that bond to the surface, creating a dense,protective coating with no alternation to the substrate structure. This combination of coating and substrate allows designers and engineers to produce products with enhanced surface properties not inherent in the original material.