PVD, CVD & thermal spray · finish comparison
HVOF Carbide Coating vs Plasma Spray Coating
HVOF Carbide Coating and Plasma Spray Coating are both thermal spray finishes; hVOF coating resists corrosion better.
HVOF Carbide Coating
Thermal spray · $$$$ · instant quote
HVOF accelerates WC-Co or Cr3C2-NiCr particles in a supersonic combustion jet to make dense 50–500 µm wear coatings.
Plasma Spray Coating
Thermal spray · $$$$ · instant quote
Plasma spray propels molten or softened ceramic or metallic powder onto a grit-blasted substrate to build 50–500 µm coatings.
When to choose which
Choose HVOF coating
Choose HVOF coating when a denser carbide wear coating is required.
- Dense carbide wear surface
- 50–500 µm practical build range
- Typical bond strength at least about 70 MPa for qualified systems
Choose Plasma spray
Choose Plasma spray when ceramic or thermal-barrier feedstock is required.
- 50–500 µm build capability
- Ceramic and metallic feedstocks
- Typical tensile bond strength about 20–70 MPa
What the numbers say
- HVOF coating resists corrosion better.
- HVOF coating is the harder surface (1,000–1,400 HV vs 500–900 HV).
- Plasma spray is the lower-cost option ($$$$).
- HVOF coating is conductive; Plasma spray is insulating.
- Plasma spray tolerates more heat (1,000 °C continuous).
Scores side by side
Each score is 0–100 against every finish in this catalog. Corrosion is derived from salt-spray test duration and surface hardness from the finish layer's Vickers hardness where a measured figure exists; a finish that leaves the base metal's own surface is not rated for hardness. Cosmetic, lubricity and cost are FabDigit's engineering assessment. Scores and typical figures are screening data, not matched side-by-side tests or service-life rankings; ASTM B117 is a controlled salt-fog method, not a field-life prediction.
| Score | HVOF coating | Plasma spray |
|---|---|---|
| Corrosion resistance | 78 Very good | 60 Good |
| Surface hardness / wear | 77 Very good | 68 Good |
| Cosmetic quality | 35 Fair | 30 Low |
| Lubricity | 35 Fair | 20 Low |
| Cost | 94 $$$$ | 88 $$$$ |
Key numbers
| Property | HVOF coating | Plasma spray |
|---|---|---|
| Thickness | 50–500 µm | 50–500 µm |
| Surface hardness | 1,000–1,400 HV | 500–900 HV |
| Max service temperature | 500 °C | 1,000 °C |
| Electrical | Conductive | Insulating |
| Colours | grey, dark grey | white, grey, black, feedstock-dependent |
| Relative cost | High ($$$$) | High ($$$$) |
| Added lead time | 12–25 working days | 10–20 working days |
| RoHS | Compliant | Compliant |
| Instant quote | Yes | Yes |
Bold marks the side that is ahead on a row where more (or less, for cost and lead time) is better. Ranges are the typical specification window; the drawing call-out fixes the class.
Which materials take each finish
| Material family | HVOF coating | Plasma spray |
|---|---|---|
| Nickel Alloy | Yes | Yes |
| Stainless Steel | Yes | Yes |
| Steel | Yes | Yes |
| Aluminum | With care | With care |
| Titanium | With care | With care |
| Brass | Limited | Limited |
| Copper Alloy | Limited | Limited |
HVOF coating vs Plasma spray — frequently asked
What is the difference between HVOF coating and Plasma spray?
HVOF Carbide Coating and Plasma Spray Coating are both thermal spray finishes; hVOF coating resists corrosion better. HVOF coating is the harder surface (1,000–1,400 HV vs 500–900 HV). Plasma spray is the lower-cost option ($$$$).
When should I use HVOF coating instead of Plasma spray?
Choose HVOF coating when a denser carbide wear coating is required. Conversely: choose Plasma spray when ceramic or thermal-barrier feedstock is required.
Is HVOF coating or Plasma spray cheaper?
Plasma spray is the lower-cost finish ($$$$ against $$$$ for HVOF coating) among the finishes FabDigit quotes. Both are priced per part with a lot minimum; the exact figure appears on the instant quote once the part is uploaded.