A wide variety of materials can be applied using thermal spray to provide different degrees of electrical conductivity. Materials such as copper and aluminium are the most popular. There is also a range of thermally sprayed oxide ceramics that can be used as conductors and semi-conductors.
Within the thermal spray industry, a complete range of dielectric coatings can be applied in high and low voltage applications. With a broad portfolio of coating materials, a dielectric coating can be produced to offer a solution for almost every difficult electrical problem. The most frequently used thermal spray dielectric materials are oxide ceramics and polymers. Ceramics are more durable, wear and corrosion resistant, and have higher dielectric strengths than polymers. Dielectric strengths from ceramic coatings vary from 300 to over 1000 volts per mil. Common materials include oxides of aluminium, titanium, and yttrium.
The increasingly high-tech, plugged-in world we live in has lead to a greater need to shield sensitive electronics from unwanted and potentially harmful electromagnetic radiation. Thermal sprayed shielding coatings can protect electronic equipment from electromagnetic interference and radio frequency interference. Thermal spray techniques are suitable for such applications. Electromagnetic interference and radio frequency interference can be mitigated with the use of thermal spray coatings. Typical thermal sprayed shielding materials are pure metals and metal alloys such as aluminium, copper, tin, and zinc.