Precision Thermal Spray Coatings That Outperform

Enhance. Protect. Engineer for Performance.

Coating Materials & Engineering Capabilities

We apply a wide range of metal and ceramic coatings to meet your design and operating requirements. Our coatings techniques are applied under carefully controlled parameters, ensuring consistent adhesion, uniform thickness, and machinability for post-coating finishing.

Metal & Alloy Coatings

Aluminum, steel, nickel, cobalt, copper, zinc, tungsten, molybdenum, and their alloys.

Ceramic Coatings

Aluminum oxide, chromium oxide, zirconium oxide, titanium oxides and other advanced ceramics.

Coating Thickness & Precision

Metal coatings: 0.001″ to 0.100″
Ceramic coatings: up to 0.020″
Surface finish: 16 microinch or better

Rocket engine exhaust plume illustrating high-temperature plasma and thermal spray technology used in aerospace coatings.

Enhance. Protect. Engineer for Performance.

At Metal Fusion, Inc., we don’t just fix worn parts — we engineer coating solutions that improve the performance, durability, and precision of your metal components before problems start.

Our thermal spray coating services combine metallurgical expertise with decades of industry experience, enabling us to apply high-performance coatings that extend equipment life, prevent corrosion, and enhance mechanical properties across critical industries.

Serving Northern California and industry leaders globally, we are a trusted resource for aerospace, energy, semiconductor, marine, and industrial manufacturers seeking coatings that meet exacting standards.

Our Expertise

We maintain complete in-house thermal spray capabilities to control quality and turnaround from start to finish.

Processes include:

Plasma Spray: High-energy process ideal for ceramic coatings with exceptional heat and corrosion resistance.
Dual Wire Arc Spray: Efficient method for applying durable metallic overlays at high deposition rates.
Fuel Wire Spray: Versatile process for general-purpose coatings and heavy-duty protection.
5P & 6P Thermal Spray: Proven systems for structural coatings, base layers, and high-build applications.

Each process is selected based on your part’s service environment, desired performance characteristics, and material compatibility.

Applications & Performance Benefits

Thermal spray coatings can transform standard components into engineered surfaces that outperform the original base metal.

Common applications include:

Wear-resistant surfaces for rotating machinery
Heat and oxidation protection for turbine and exhaust parts
Dimensional build-up on precision-engineered components
Corrosion-resistant coatings for marine or chemical environments
Electrical and thermal barrier coatings for advanced systems

Performance Advantages

Increased wear life & fatigue strength
Improved corrosion & heat resistance
Controlled friction & sealing properties
Dimensional precision for tight tolerances
Reduced maintenance & lifecycle cost

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Our Commitment to Quality

At Metal Fusions Inc. (MFI), every project goes through rigorous inspection, precision machining, and FAA-approved testing to ensure absolute reliability. Whether it’s a one-off component or a mission-critical aerospace part, our small-batch, high-value focus guarantees uncompromising quality on every project.

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