Flame spray, also known as oxy/acetylene combustion spray is the original thermal spray technique developed nearly 90 years ago. It uses the basic principles of a welding torch with the addition of a high velocity air stream to propel molten particles onto the substrate. The coating material can be either a wire or powder form. Often flame spray coatings are fused after being applied to enhance bond strengths and coating density.

Electric wire arc thermal spraying utilizes the same principles employed in wire arc welding systems. The coating material, in wire form, is electrically charged, then contacted creating an arc. The molten droplets of metal wire are then sprayed onto the substrate using a high velocity air stream to atomize and propel the material.

The plasma spray process (non-transferred arc), uses inert gases fed past and electrode inducing the "plasma" state of the gases. When the gases exit the nozzle of the gun apparatus and return to their normal state, a tremendous amount of heat is released. A powdered coating material is injected into the plasma "flame" and propelled onto the substrate.

The HVOF process combusts oxygen and one of select group of ignitable gases including: propane, propylene, or hydrogen. Although the HVOF system uses the basic principle of combustion, the spray gun is designed differently than the standard oxy-fuel spray gun. The HVOF gun differences produce higher flame temperatures and higher velocities. The result is more thoroughly melted powder and more kinetic energy available to "flatten" the molten particles of coating material. The HVOF process produces superior bond strength and coating density.