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Metal Coatings HVOF: High Velocity Oxy-Fuel
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HVOF: High Velocity Oxy-Fuel Spray Coating

Electro-Coatings provides High Velocity Oxy-Fuel (HVOF) coating services. HVOF is a high-velocity combustive spray, also known as flame spray coating or thermal plasma coating, that delivers exceptional resistance to wear and corrosion.

High Velocity Oxy-Fuel (HVOF) Coatings

HVOF is applied via flame spray; a spray head that mixes oxygen and a combustible fuel (a mix of kerosene, acetylene, propylene and hydrogen) to deliver a powdered friction-reducing coating material. The resulting mixture is sprayed in a jetlike effect at extreme temperatures between 5000-6000°F at velocities of more than 7000 feet per second.

The extreme heat and spray pressure of HVOF combine to produce a coating of exceptional hardness, outstanding adhesion to the substrate material, and substantial resistance to corrosion. HVOF generally exceeds bond strengths of 12,000 psi between the coating and substrate, which allows HVOF coatings to maintain nearly 100% of their wear and corrosion resistance in high-temperature environments.

This high level of bond strength also makes HVOF coatings useful for component repair. HVOF coatings may be applied in thicknesses of up to 1/2" without compromising their strength, making it possible to restore worn component surfaces with no additional machining required.

Features and Benefits:

Like many Electro-Coatings products, HVOF provides multiple benefits. HVOF is an excellent choice for those needing high resistance to both wear and corrosion.

  • High-velocity spray brings better adhesion to substrates
  • High temperature delivers extremely low coating porosity for better corrosion resistance
  • The combustion-based system delivers better hardness coefficient for improved wear resistance
  • Combined pressure and heat result in smoother coating finish
  • Ceramic or metallic coatings may be applied to 12mm (1/2") thick


High Velocity Oxy-Fuel (HVOF) coatings fight corrosion by enhancing the surface consistency, hardness and bond strength of many coating types, including tungsten carbide, chrome carbide, nickel alloys, cobalt alloys and various carbon and stainless steels. The HVOF process centers around a flame spray -- spray head that mixes oxygen, a combustible fuel (kerosene, acetylene, propylene and hydrogen) and a powdered friction-reducing coating material. A jet-like nozzle delivers coatings at temperatures of 5-6000o F at velocities beyond 7000 feet per second. HVOF allows coatings to maintain their corrosion resistant properties in high temperature environments, or in applications which must endure mechanical stress from high levels of friction.

Materials and Applications of HFOV Coatings

Typical HFOV coatings include:

  • Nickel & cobalt based alloys
  • Stellite
  • Triballoy
  • Inconel
  • Iron Based Alloys
  • AISI 316L
  • Carbides & Cermets
  • MCrAlY

HFOV coating’s protective properties can be used for several different applications including, but not limited to:

  • Crankshaft conditioning or reconditioning
  • Fouling protection
  • Altering thermal or electric conductivity
  • Wear control: hardfacing or abradable coating
  • Repair damaged surfaces
  • Protection from temperature or oxidation
  • Medical implants
  • Production of functionally graded materials

HVOF coating experts

Successful HVOF spray coating requires extensive experience. The HVOF coating experts at Electro-Coatings have the background and the latest equipment to produce high temperature coatings that are both first-class quality and affordable.

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