Optimizing Powder Usage in Thermal Spray & Laser Cladding
- Dan Haas
- Mar 18
- 3 min read
The Role of Weight Loss Powder Feeders
Thermach recently launched a new powder feeder: The AT-1200WL Weight Loss Powder Feeder. The AT-1200WL facilitates consistent powder delivery throughout the volume cycle.
The following technical post will provide detail of other benefits your coating operation will realize by utilizing the new AT-1200WL. These include powder consumption control, cost efficiency and coating consistency. Also, the addition of a pinch valve for immediate powder flow control provides an additional level of efficiency, reducing waste and improving overall process reliability.
In thermal spray and laser cladding applications, achieving consistent coating quality while managing material costs is a top priority. One of the biggest challenges in these processes is ensuring precise powder delivery. Traditional volumetric powder feeders rely on a fixed delivery rate, but variations in powder characteristics—such as density, flowability, and moisture content—can lead to fluctuations that result in overuse of powder, uneven coatings, and increased process costs.
How a Weight Loss Powder Feeder Improves Efficiency
A weight loss powder feeder addresses these challenges by continuously monitoring and adjusting the feed rate based on actual weight reduction over time. This ensures a more accurate and stable powder delivery, leading to:
Improved Process Efficiency – Consistent powder feed rate leads to uniform coatings, reducing rework and improving quality.
Material Cost Savings – More precise powder usage minimizes waste, making the process more economical over time.
Easier Changeovers & Maintenance – A quick-change canister can allow for seamless transitions between powders and simplifies cleaning.
Real-Time Monitoring & Control – Integrated trend data tracking helps detect feed inconsistencies early, improving troubleshooting and process stability.
Operational Flexibility – Having the system capable of operating in standalone or remote mode, makes it adaptable to different production environments.
Pinch Valve for Instant Flow Control – Integrating a pinch valve allows for immediate shutoff of powder flow, reducing excess powder consumption and preventing unnecessary waste.
Understanding Powder Costs and Waste Impact
Powder materials used in thermal spray and laser cladding vary widely in cost depending on composition, purity, and particle size. Cost per kilogram can range from $20/kg to over $1,000/kg, depending on the specific alloy, size and grade of powder:
Powder Type | Approximate Cost (per kg) |
Aluminum Oxide | $20/kg |
Tungsten Carbide | $40/kg |
High-End Thermal Spray Powder | $990/kg |
Given these costs, inefficient powder usage can quickly result in significant financial losses.
Real-World Example: The Cost of Waste
Consider a scenario where a user is depositing 10 kg/hour of powder with an average 10% of excess deposit:
Excess per hour = 10 kg × 10% = 1 kg/hour
Time to accumulate 5 kg waste = 5 hours
Estimated cost loss over 5 hours:
Aluminum Oxide ($20/kg): $100
Tungsten Carbide ($150/kg avg.): $200
High-End Thermal Spray Powder ($990/kg): $4,950
This example highlights how even small variations in feed rate can lead to substantial excess material costs over a single shift.
Solution
Using the new AT-1200WL Weight Loss Powder Feeder with an integrated Pinch Valve for Instant Flow Control, the system minimizes unnecessary material loss, preventing powder from continuing to flow when not needed. This on top of the consistent powder delivery throughout the volume cycle delivered by the AT-1200WL.
A weight loss powder feeder from Thermach will improve your process efficiency. Share your experiences with powder management in your operation!
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Thermach continues to be on the leading edge of the thermal spray industry. We are launching next generation equipment and consumables throughout 2025.
Remember, Thermach is not your competitor; your other options are. We don’t coat; we only supply thermal spray equipment and parts. You can proceed with confidence, knowing that our team is dedicated to creating a custom system that meets your exact specifications.
Manufacturer of Equipment & Parts for the Thermal Spray Industry. Backed by Reliable, Timely Service & Support.
Thermach manufactures thermal spray coating systems for the coating industry. We don't coat. We provide the equipment and parts necessary for you to run a successful coating operation. Our mission is to ensure your coating process is running smoothly with Thermach equipment.
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