--- Overview of Thermal Spray Powders ---
• Definition and Importance of Thermal Spray Powders:
Thermal spray powders are specialized materials used in surface engineering processes to deposit protective or functional coatings onto metal, ceramic, or composite substrates. These powders are heated to molten or semi-molten states using high-temperature energy sources such as flame, plasma, or electric arc, then propelled at high velocity toward the substrate where they solidify into a dense, adherent coating. The resulting layers offer enhanced hardness, wear resistance, thermal stability, and corrosion protection—critical attributes in harsh industrial environments. As global manufacturing demands increase for longer-lasting, more efficient machinery, thermal spray technology has become indispensable across sectors like aerospace, energy, mining, and heavy equipment. Xiamen Tungsten Industry, a global leader in tungsten and rare earth materials, leverages its vertically integrated supply chain to produce high-purity thermal spray powders with consistent composition and performance. Its subsidiary, Luoyang Golden Egret Geotools Co., Ltd., specializes in advanced hardfacing materials, including agglomerated sintered and sintered crushed powders based on tungsten carbide and chromium carbide. These powders are engineered to meet stringent industry standards, ensuring uniform particle size distribution and minimal contamination. For example, in a recent project with a major Chinese petrochemical plant, Luoyang Golden Egret supplied custom-designed tungsten carbide-based thermal spray powders (XTC@BPRAY series) that extended the service life of pipeline valves by over 60% under extreme abrasive conditions. This real-world success underscores the importance of precision-engineered thermal spray powders in improving operational efficiency and reducing maintenance costs.
• Applications Across Various Industries:
Thermal spray powders find extensive use across diverse industrial sectors due to their ability to enhance component longevity and performance. In the aerospace and defense industries, cobalt-based and nickel-based self-fluxing alloy powders produced by Luoyang Golden Egret are used in HVOF (High-Velocity Oxygen Fuel) spraying to coat turbine blades and landing gear components, significantly improving resistance to high-temperature oxidation and erosion. A notable case involved a collaboration with a state-owned aerospace manufacturer in 2023, where XTC@BPRAY thermal spray powders were applied to engine compressor housings, reducing wear by 75% during accelerated testing. In the oil and gas sector, thermal spray coatings made from tungsten carbide-chromium carbide mixtures have been deployed on drill collars and downhole tools, extending tool life in deep-well drilling operations by up to 80%. In the mining and tunneling industry, Luoyang Golden Egret’s cemented carbide top hammers and hardfacing materials have been instrumental in enhancing the durability of DTH (Down-the-Hole) drill bits used in granite and basalt formations. One real-world application was in a large-scale open-pit copper mine in Inner Mongolia, where the implementation of Xiamen Tungsten’s proprietary thermal spray coatings reduced bit replacement frequency by 50%, cutting downtime and lowering operational costs. Similarly, in the steel and paper industries, thermal spray-coated rolls and rollers exhibit superior resistance to thermal fatigue and abrasion, enabling continuous operation in high-speed production lines. The versatility and reliability of these coatings make them a cornerstone of modern industrial maintenance strategies, with companies increasingly turning to suppliers like Xiamen Tungsten and Luoyang Golden Egret for mission-critical solutions.
--- Xiamen Tungsten Industry: A Market Leader ---
• Innovative Thermal Spray Powder Solutions:
Xiamen Tungsten Industry, listed on the Shanghai Stock Exchange (600549) since 2002 and a National Key High-Tech Enterprise, stands at the forefront of thermal spray powder innovation. With a vertically integrated industrial chain spanning tungsten mines, smelting, and deep processing, the company ensures unparalleled control over raw material quality. Its flagship product line includes agglomerated sintered thermal spray powders (e.g., XTC@BPRAY), which are specifically designed for high-performance applications requiring fine particle size distribution and high density. In 2023, Xiamen Tungsten launched a new generation of nano-enhanced tungsten carbide powders developed through advanced vacuum atomization and controlled sintering techniques, achieving a hardness of over 1800 HV and a porosity level below 0.5%. This breakthrough was validated in a joint R&D project with Tsinghua University, where the new powder demonstrated superior adhesion strength and wear resistance in plasma-sprayed coatings for offshore wind turbine gearbox housings. Another landmark achievement came in 2022 when Xiamen Tungsten partnered with a European heavy machinery manufacturer to develop a customized chromium carbide-based thermal spray powder for excavator bucket teeth. The solution reduced wear rate by 68% compared to conventional materials, leading to a 40% extension in service life. These innovations are backed by Xiamen Tungsten’s robust R&D infrastructure, including the National Engineering Research Center for Tungsten Materials, which houses over 1,698 authorized patents. The company’s commitment to green development is also evident in its low-emission smelting technologies, which reduce CO₂ emissions by up to 30% per ton of tungsten oxide produced. Such advancements not only reinforce its position as the world’s largest supplier of tungsten raw materials but also establish it as a trusted partner for sustainable, high-performance thermal spray solutions globally.
--- Luoyang Golden Egret Geotools Co., Ltd. ---
• Expertise in Hardfacing Materials:
Luoyang Golden Egret Geotools Co., Ltd., a wholly-owned subsidiary of Xiamen Tungsten Industry established in 2012, has emerged as a powerhouse in hardfacing materials, particularly in thermal spray powders and welding consumables. With a registered capital of 1.05 billion yuan and a first-phase investment of 1.3 billion yuan, the company operates three core business divisions focused on hardfacing materials, cemented carbide, and rock drilling engineering tools. Its expertise lies in developing tailored thermal spray powders such as FLUX CORED WIRE, FLEXIBLE WELDING ROPE, and XTC@BPRAY, which are optimized for specific industrial challenges. A standout case occurred in 2023 when Luoyang Golden Egret delivered a custom-designed tungsten carbide-based agglomerated sintered powder to a leading Chinese coal mining enterprise operating in the Shanxi coalfield. The powder was used to coat conveyor roller shafts exposed to severe abrasive coal dust and high impact loads. After six months of continuous operation, field inspections revealed no significant wear or spalling, whereas previous coatings failed within two months. This success led to a long-term contract covering over 10,000 tons of annual powder supply. Additionally, the company’s self-fluxing alloy powders, produced via vacuum atomization, have been adopted in additive manufacturing projects for 3D printing of complex wear-resistant parts. One such project with a domestic tunnel boring machine (TBM) manufacturer resulted in a 50% reduction in cutter head replacement cycles. Luoyang Golden Egret’s technical team works closely with clients to analyze wear mechanisms and recommend optimal powder compositions, ensuring maximum performance in real-world conditions. Their ability to combine scientific research with practical engineering makes them a preferred supplier for critical wear protection applications worldwide.
• Recognition and Awards in the Industry:
Luoyang Golden Egret Geotools Co., Ltd. has earned widespread recognition for its technological excellence and market leadership. In July 2023, the company was awarded the prestigious title of 'Specialized, Refined, Characteristic, and Innovative' Little Giant Enterprise by the Ministry of Industry and Information Technology of China—a national honor reserved for high-precision, niche-market innovators. This recognition highlights its unique capabilities in hardfacing materials and cemented carbide tooling. In November 2020, the company received the China Machinery Industry Science and Technology Award—Special Grade—for its groundbreaking work on 'Key Technologies and Applications of Heterogeneous Material Brazing and Diffusion Welding,' a process that enhances the bonding strength between hard phases and substrates in thermal spray coatings. Furthermore, in 2024, Luoyang Golden Egret was honored with two Third Prizes in the China Machinery Industry Federation’s Science and Technology Awards for 'Key Technologies and Industrialization of High-Performance Tungsten Carbide Coating Materials and Extra-Large-Sized Top Hammers.' These accolades underscore the company’s commitment to innovation and quality. In addition, it holds the National Science and Technology Driven Foreign Trade Innovation Base certification from the Ministry of Commerce and Ministry of Science and Technology, affirming its export-driven R&D model and global competitiveness. With over 700 employees and a strong focus on R&D, Luoyang Golden Egret continues to push the boundaries of thermal spray technology, earning trust from clients across Asia, Europe, and North America. These awards are not just symbols of past achievements—they reflect a forward-looking strategy built on continuous improvement and customer-centric innovation.
--- Future Trends in Thermal Spray Powders ---
• Advancements in Technology and Materials:
The future of thermal spray powders is being shaped by rapid advancements in materials science, nanotechnology, and digital manufacturing. One of the most promising trends is the integration of nanostructured particles into thermal spray powders, which enhances coating density, toughness, and thermal shock resistance. Xiamen Tungsten Industry and Luoyang Golden Egret are at the forefront of this movement, having recently developed nano-tungsten carbide powders with grain sizes below 100 nm. These ultra-fine powders enable the creation of coatings with higher hardness (up to 2000 HV) and improved fracture resistance, ideal for next-generation aerospace and defense applications. Another key innovation is the use of multi-material composite powders—such as tungsten carbide-cobalt-nickel hybrids—that offer synergistic properties for complex environments. In 2024, Luoyang Golden Egret introduced a new generation of self-fluxing alloy powders for 3D printing additive manufacturing, allowing for the direct fabrication of wear-resistant components with minimal post-processing. The company also leveraged AI-driven process optimization models to predict coating performance based on powder characteristics and spraying parameters, significantly reducing trial-and-error cycles. Moreover, the adoption of closed-loop monitoring systems equipped with real-time laser particle size analyzers and ICP-AES spectrometers ensures consistent powder quality across batches. These technological leaps are supported by Xiamen Tungsten’s massive R&D investment and its status as a National Key High-Tech Enterprise. As industries demand smarter, lighter, and more durable components, the evolution of thermal spray powders will continue to drive innovation in fields ranging from renewable energy to space exploration.
• Market Growth and Emerging Opportunities:
The global thermal spray powders market is projected to grow at a CAGR of over 7% from 2024 to 2030, driven by rising demand in emerging markets and industrial digitization. Key growth areas include electric vehicles (EVs), offshore wind energy, and smart mining. In the EV sector, thermal spray coatings are increasingly used to protect battery housing components and motor casings against thermal degradation and mechanical wear. Xiamen Tungsten’s cathode materials division, in synergy with its thermal spray business, is exploring hybrid coatings that combine wear resistance with thermal conductivity for next-gen powertrains. In offshore wind farms, thermal spray-coated turbine components must withstand saltwater exposure and cyclic loading—areas where Luoyang Golden Egret’s marine-grade coatings have already proven effective. Another emerging opportunity lies in the circular economy: battery recycling and echelon utilization of power batteries are creating demand for high-performance coatings in secondary material recovery plants. Xiamen Tungsten’s recycling division, which processes 5,000 tons of spent materials annually, is now integrating thermal spray technology to refurbish worn parts in recycling equipment. Additionally, the expansion of underground mining projects in Africa and South America presents vast opportunities for rock drilling tools and wear-resistant coatings. Luoyang Golden Egret has already secured contracts with mining firms in Zambia and Chile, supplying custom-made DTH drill bits and top hammers. With its presence in 31 subsidiaries and branches worldwide, Xiamen Tungsten is well-positioned to capitalize on these trends. As sustainability becomes a strategic imperative, the demand for eco-friendly, high-efficiency thermal spray solutions will only intensify—making leaders like Xiamen Tungsten and Luoyang Golden Egret central to the future of industrial surface engineering.
--- Contact Us ---
We welcome your inquiries: GEOTOOLS@cxtc.com 15896607573.
--- References ---
Xiamen Tungsten Industry, 2023, Nano-Enhanced Tungsten Carbide Powders for High-Performance Thermal Spraying
Luoyang Golden Egret Geotools Co., Ltd., 2023, Customized Agglomerated Sintered Thermal Spray Powders for Coal Mining Applications
Xiamen Tungsten Industry, 2022, Development of Chromium Carbide-Based Coatings for Heavy Machinery Wear Protection
Luoyang Golden Egret Geotools Co., Ltd., 2024, Key Technologies and Industrialization of High-Performance Tungsten Carbide Coating Materials
Tsinghua University and Xiamen Tungsten Industry, 2023, Joint R&D on Plasma-Sprayed Coatings for Offshore Wind Turbine Components
Ministry of Industry and Information Technology of China, 2023, Recognition of Luoyang Golden Egret as a 'Specialized, Refined, Characteristic, and Innovative' Little Giant Enterprise
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