Thermal Spray Technologies in Additive Manufacturing: A Comprehensive Review of Techniques and Industrial Applications

Abhishek  Raj

doi:10.69968/ijisem.2025v4i2259-266

Authors

Abhishek Raj Assistant Professor, Production & Industrial Engineering Department, B.I.T.Sindri, Jharkhand

DOI:

https://doi.org/10.69968/ijisem.2025v4i2259-266

Keywords:

Thermal Spray Coatings, Additive Manufacturing (AM), D-gun, Plasma spraying, Cold Spraying, Flame Spraying, High Velocity Air Fuel (HVAF), High Velocity Oxy-Fuel Coating (HVOF)

Abstract

For many years, thermal spraying techniques have been extensively used for component preservation and reclamation in all of the main engineering industry areas. The prospective application range of thermally sprayed coatings has been expanded and the quality has been enhanced as a result of recent apparatus and process developments. The article reviews a number of literature studies on additive manufacturing and thermal spray. It concluded that thermal spray coatings have demonstrated immense potential in enhancing the surface properties of additive manufactured components across industries such as automotive, biomedical, power generation, and aerospace. Techniques like HVOF, D-gun, and plasma spraying offer superior wear, corrosion, and heat resistance, especially in harsh environments. The integration of nano-structured and rare earth materials further improves coating performance. With advancements in AM and increasing demand for durable, high-performance parts, the synergy between thermal spray and AM is pivotal. This fusion not only strengthens component life but also supports green manufacturing, paving the way for a more sustainable industrial future.

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