Thermal Spray Coating involves melting or heating of powder or wire feedstock using special torches, accelerating the particles towards the part to be coated where they impact and cool to form a coating. Generally any material without a sublimation point can be deposited using this technique.

Thermal spray can be used to apply high performance performance surfaces to resist wear, corrosion or heat damage. Thermal Spray Coating can also be applied for special applications such as electrical insulation or conduction, x-ray emission and thermal emission. A common application is build up and repair of worn components.