The cost of repairing the component is less than buying a new one. Often, the coating actually lasts longer than the original material used.
With few exceptions, the thermal spray process leaves the component’s thermal history alone.
Almost any metal, ceramic or plastic can be thermal sprayed.
Depending on the material and spray system, coatings can be sprayed from 0.001 to more than 1 inch thick. The thickness typically ranges from 0.005-0.1 inch.
The spray rates range from 3-60 lb/hr depending on the material and the spray system. Typical rates for material application are 1/2 -2 lb of material per sq ft per 0.01 inch thickness.