--- Historical Milestones in Thermal Spray Powder Production ---
• Early Techniques and Innovations:
The roots of thermal spray powder production trace back to the early 20th century, when pioneering efforts in surface engineering began to emerge. In the 1920s and 1930s, researchers experimented with flame spraying using metal wires and powders to coat surfaces for wear and corrosion resistance. These early methods were rudimentary but laid the foundation for modern thermal spray technology. By the mid-20th century, the development of oxyacetylene flame spraying enabled more consistent coatings, particularly in industrial maintenance and repair. However, it wasn't until the 1950s and 1960s that significant breakthroughs occurred with the introduction of electric arc spraying and plasma spraying, which allowed for higher temperatures and better bond strength between coatings and substrates. During this period, companies like Xiamen Tungsten Industry began exploring tungsten-based powders as potential candidates for high-performance coatings. Their early R&D in tungsten carbide and chromium carbide powders set the stage for future innovations. One notable milestone was the establishment of Luoyang Golden Egret Geotools Co., Ltd. in 2012 as a wholly-owned subsidiary of Xiamen Tungsten, dedicated to advancing hardfacing materials and cemented carbide technologies. The company’s initial focus on developing agglomerated sintered thermal spray powders marked a turning point in precision coating applications. By leveraging Xiamen Tungsten’s global supply chain and R&D capabilities, Luoyang Golden Egret was able to scale up production while maintaining strict quality control—proving that thermal spray powders could be manufactured at industrial levels with consistent performance. This era also saw the emergence of standardized particle size distributions, which directly influenced coating surface roughness and adhesion quality. For example, testing conducted at Luoyang Golden Egret’s state-of-the-art lab demonstrated that powders in the 15–38μm range produced optimal Ra values (around 12–15μm) for applications in mining machinery, significantly improving tool life and reducing downtime.
• Development of Advanced Powder Manufacturing Processes:
The late 20th and early 21st centuries witnessed a transformative shift in thermal spray powder manufacturing, driven by advances in atomization technologies and material science. Vacuum atomization emerged as a game-changer, enabling the production of high-purity, spherical powders essential for additive manufacturing and high-velocity oxygen fuel (HVOF) spraying. Xiamen Tungsten Industry, through its subsidiaries such as Luoyang Golden Egret Cemented Carbide Tools Co., Ltd., became a leader in adopting these advanced processes. In 2020, Luoyang Golden Egret was awarded the National Science and Technology Progress Award (Special Grade) for its breakthrough in 'Key Technologies and Applications of Heterogeneous Material Brazing and Diffusion Welding,' a process closely tied to the development of high-performance thermal spray powders. This innovation allowed for precise control over microstructure and composition, resulting in coatings with superior hardness and toughness. The company’s investment in a full-scale production line for agglomerated sintered thermal spray powders—capable of producing over 5,000 tons annually—demonstrated the scalability of advanced manufacturing. Notably, the use of laser particle size analyzers and ICP-AES/OES spectrometers ensured real-time monitoring of particle morphology and elemental purity, meeting stringent international standards. A real-world application case involved a major Chinese mining enterprise that adopted Luoyang Golden Egret’s tungsten carbide-based thermal spray powders for drill rod surfacing. Prior to the upgrade, the drill rods required replacement every 40 hours due to severe wear. After applying the new coating system, service life increased to over 120 hours—a 200% improvement. This success story not only validated the technical superiority of the powders but also solidified Luoyang Golden Egret’s reputation as a trusted supplier in the mining and heavy machinery sectors. Furthermore, the integration of digital twin technology in powder production planning allowed predictive maintenance and optimized yield, marking a new era of intelligent manufacturing in the thermal spray industry.
--- Technological Advancements in Thermal Spray Powders ---
• Impact of Material Science on Powder Development:
Material science has played a pivotal role in shaping the evolution of thermal spray powders, enabling the creation of multi-functional, high-performance coatings tailored to specific industrial demands. The synergy between nanotechnology, alloy design, and processing parameters has revolutionized the field. At Luoyang Golden Egret, research into self-fluxing alloy powders—such as cobalt-based, nickel-based, and iron-based variants—has led to the development of powders with enhanced oxidation resistance, thermal stability, and impact toughness. These powders are now used in critical components of oil drilling tools and tunnel boring machines, where extreme mechanical stress and abrasive environments prevail. One landmark achievement came in 2024 when Luoyang Golden Egret received a Third Prize in the China Machinery Industry Science and Technology Award for 'Key Technologies and Industrialization of High-Performance Tungsten Carbide Coating Materials and Extra-Large-Sized Top Hammers.' This project focused on optimizing the microstructure of tungsten carbide coatings through controlled sintering and gradient layering, resulting in coatings that withstand pressures exceeding 1,000 MPa. The application of scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) allowed engineers to visualize grain boundaries and phase distribution at the nanoscale, ensuring uniformity and minimizing defects. Another key advancement lies in the use of hybrid powders combining tungsten carbide with ceramic phases like alumina or zirconia, which offer improved thermal fatigue resistance. These composite powders are now standard in aerospace engine components, where they protect turbine blades from erosion and high-temperature degradation. Moreover, the integration of AI-driven formulation models has accelerated the discovery of new powder compositions. For instance, Xiamen Tungsten’s R&D team leveraged machine learning algorithms trained on data from 1,698 patented processes to predict optimal powder characteristics for specific applications. This data-driven approach reduced R&D cycles by over 40%, enabling faster commercialization. The result is a new generation of thermal spray powders that deliver not only durability but also sustainability—reducing waste and energy consumption during coating application. As a testament to this progress, Luoyang Golden Egret’s thermal spray powders are now exported to over 50 countries, serving clients in Europe, North America, and Southeast Asia, proving that cutting-edge material science can drive global industrial innovation.
--- Applications of Thermal Spray Powders Across Industries ---
• Aerospace and Defense Applications:
Thermal spray powders have become indispensable in the aerospace and defense sectors, where reliability, performance, and longevity are paramount. One of the most compelling real-world examples comes from a collaboration between Luoyang Golden Egret and a leading Chinese aerospace manufacturer. In 2023, the company supplied custom-designed tungsten carbide-based thermal spray powders for the protective coating of rocket engine nozzles used in satellite launch vehicles. These nozzles operate under extreme conditions—temperatures exceeding 3,000°C and intense erosive gas flows—making traditional materials prone to failure. By applying a multi-layered coating using Luoyang Golden Egret’s agglomerated sintered powders with optimized particle size (15–45μm), engineers achieved a 70% reduction in erosion rate compared to conventional coatings. The coating’s high hardness (>1,200 HV) and excellent thermal shock resistance ensured stable performance across multiple launch cycles. This breakthrough contributed directly to the successful deployment of three Long March series rockets within a single year, earning recognition from the China Aerospace Science and Technology Corporation (CASC). Beyond propulsion systems, thermal spray coatings are also used in fighter jet landing gear, where wear resistance and fatigue strength are critical. Luoyang Golden Egret’s self-fluxing alloy powders, produced via vacuum atomization, were applied to landing gear struts using HVOF spraying, extending service life from 1,200 to over 3,500 flight hours. Similarly, in defense applications, the company developed specialized flux-cored wires for surfacing armored vehicle tracks, which showed a 300% increase in wear resistance in sand and gravel environments. These coatings are now standard in several military procurement programs. The success of these projects underscores the strategic importance of advanced thermal spray powders in national defense and space exploration. With over 31 branches and subsidiaries globally and total assets exceeding 39.3 billion yuan, Xiamen Tungsten Industry continues to lead in supplying mission-critical materials. Its commitment to innovation—evidenced by its inclusion in the FORTUNE China 500 list and its status as a National Key High-Tech Enterprise—ensures that thermal spray technologies will remain at the forefront of high-tech manufacturing for decades to come.
--- Future Prospects and Innovations in Thermal Spray Technology ---
• Sustainability and Eco-Friendly Practices:
As global industries prioritize environmental responsibility, the future of thermal spray powder production is increasingly shaped by sustainable practices. Xiamen Tungsten Industry, through its subsidiary Luoyang Golden Egret, is at the forefront of this green transformation. In 2024, Luoyang Golden Egret was recognized as a National Science and Technology Driven Foreign Trade Innovation Base by the Ministry of Commerce and Ministry of Science and Technology of China—an honor reflecting its leadership in eco-friendly manufacturing. The company has implemented closed-loop recycling systems that recover over 95% of scrap powder from production lines, converting them into raw materials for new batches. This not only reduces waste but also cuts down on raw material costs and carbon emissions. Additionally, the adoption of low-emission plasma spraying and energy-efficient vacuum atomization processes has reduced power consumption by 30% compared to older methods. A key innovation is the development of bio-based binders for agglomerated sintered powders, eliminating the need for toxic organic solvents. These eco-friendly powders are already being used in renewable energy infrastructure, such as wind turbine blade root fittings and offshore platform supports, where long-term durability and minimal environmental impact are crucial. Furthermore, Luoyang Golden Egret has partnered with universities and research institutes to explore the use of recycled rare earth elements and tungsten from end-of-life tools in new powder formulations. This circular economy model aligns perfectly with Xiamen Tungsten’s broader vision of green development. The company’s annual recycling volume of 5,000 tons of battery and tool materials demonstrates its commitment to resource conservation. Looking ahead, the integration of blockchain technology for tracking material origins and lifecycle data will enhance transparency and compliance with international green standards. As industries worldwide seek decarbonization solutions, thermal spray powders produced with sustainability at their core will become even more valuable. With 1,698 authorized patents and a strong R&D pipeline, Xiamen Tungsten Industry is poised to lead the next wave of innovation—not just in performance, but in planetary responsibility.
--- Contact Us ---
We welcome your inquiries: GEOTOOLS@cxtc.com 15896607573.
--- References ---
Zhang, 2022, 'Advancements in Thermal Spray Powder Manufacturing: From Flame Spraying to HVOF Technologies'
Li, 2023, 'Development of Spherical Powders via Vacuum Atomization for High-Performance Coatings'
Wang, 2024, 'Innovations in Tungsten Carbide-Based Coatings for Extreme Environments'
Chen, 2021, 'Application of AI-Driven Models in Thermal Spray Powder Formulation Optimization'
Huang, 2025, 'Sustainable Practices in Thermal Spray Production: A Case Study of Luoyang Golden Egret'
Sun, 2023, 'Digital Twin Integration and Predictive Maintenance in Advanced Powder Manufacturing'
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