High Velocity Oxygen Fuel (HVOF)

HVOF is a thermal spray process that uses oxygen and a combustible fuel to produce a low heat, high density, mechanically bonded coating that has extremely low porosity and high bond strength. Typical coatings include tungsten carbide, chrome carbide, stainless steel, Inconel and Monel.

Common HVOF applications include:

Aerospace & Defence

  • Landing gear, internal and external surfaces


  • PCPD and PCP rotors
  • Bottom hole assembly component parts
  • Turbomachinery component parts


  • Cylinder rods
  • Suspension rods
  • Drive shafts

Petrochemical & Refining

  • Turbomachinery component parts
  • Valve components

Plastic and polymer processing

  • Extrusion and injection screws (OD)
  • Extrusion and injection barrels (ID)
  • Mixer and valve bodies

Features and Benefits - HVOF

High kinetic energy process leads to high bond strengths (greater than 12,000 psi)

Benefit: An overlay well suited for high impact resistance

Produces extremely dense, low porosity coatings, typically less than 0.5%

Benefit: Highly corrosion resistant coating

Low residual stress allows application of a thick coating

Benefit: Extends the number times used components can be salvaged and returned to service

Rapid application process

Benefit: Allows for quick component turnaround

High impact velocities and small powder sizes result in smooth as sprayed coating

Benefit: Can be applied to complex geometry outside diameter components

Low heat input - process can be controlled to keep substrate temperatures below 300°F

Benefit: Versatility to service a broad range of components

Services and Technologies

Learn about CASL’s service and technology offerings. Our industry solutions provide the best in class services to meet the demands of your business.

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    Weld Overlay

  • thermalspray-01

    Thermal Spray

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  • component-01

    Component Remanufacturing

  • CASL_icon_HaloJet

    HaloJet ID HVOFTM System

  • overlaidpiping-01

    Overlaid Spools

  • FieldService-01

    Field Service

  • machiningfinishing-01

    Machining & Finishing

  • research-01

    Research & Development

  • CASL_icon_coatingsmaterial

    Coating Materials