Other T/S processes

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Simple Combustion Process:
In the simple combustion process, energy is generated by the combustion between oxygen and a combustible gas such as propane inside a torch and the powder is fed through a powder port and the resulting coating deposited on to a substrate material. This process has been used to deposit abradable materials such as nickel-graphite and the like. Very high thicknesses of nickel-graphite have been successfully deposited using this process. This has been the forerunner to the now-popular HVOF process. The Metco 6P torch has been used for several decades to accomplish this type of coating. As a sidenote, in depositing nickel-graphite coatings, powder settling becomes a major problem -- powders must be properly blended and kept hot so they will flow easily and form uniform microstructures.
Low Pressure Plasma Spray:
In the LPPS method, coating is accomplished in a vacuum chamber -- this therefore results in oxide levels in low-pressure plasma sprayed coatings to be very low. This has been successfully used in developing thick Co-NiCrAlY coatings, titanium-6Al-4V dental implant coatings as well as some high quality titanium-carbide coatings. Key to watch out for is to also check leak-up rates in the powder feed system, since that can cause leak-contamination in the vacuum chamber.
Simple Wire Gun Process:
Unlike the twin wire-arc process, here there is only one wire involved. Used extensively in aluminizing applications, this has been used for decades successully with a post diffusion heat treatment.