--- The Evolution of Thermal Spray Technology ---
• Historical Milestones in Thermal Spray Development:
The roots of thermal spray technology trace back to the early 20th century, with the first practical application emerging in the 1910s when researchers began experimenting with flame spraying for protective coatings. Over the decades, this field evolved significantly, culminating in the development of high-velocity oxygen fuel (HVOF) and plasma spraying technologies in the 1970s and 1980s—marking a turning point in coating quality and adhesion. The 1990s saw the rise of advanced powder production techniques such as gas atomization and vacuum atomization, which enabled precise control over particle size, morphology, and chemical composition. These innovations laid the foundation for modern high-performance thermal spray powders. Notably, companies like Xiamen Tungsten Industry, a national key high-tech enterprise and one of China’s first innovative enterprises, have played a pivotal role in advancing these technologies. Since its listing on the Shanghai Stock Exchange in 2002 and the STAR Market in 2021, Xiamen Tungsten has invested heavily in R&D, achieving breakthroughs in tungsten-based and chromium carbide-based powders. Their integrated industrial chain—from tungsten ore mining to deep processing and recycling—has positioned them as the world’s largest supplier of tungsten raw materials and alloys. This historical momentum has directly fueled progress in thermal spray powder manufacturing, enabling consistent, scalable, and high-purity materials essential for demanding industrial applications.
• Key Innovations in Powder Manufacturing:
One of the most significant advancements in thermal spray powder manufacturing lies in the refinement of powder production processes. Luoyang Golden Egret Geotools Co., Ltd., a wholly-owned subsidiary of Xiamen Tungsten Industry established in 2012, has emerged as a leader in this domain. Through proprietary vacuum atomization technology, the company produces ultra-fine, spherical self-fluxing alloy powders used in HVOF spraying, laser cladding, and 3D printing additive manufacturing. Their agglomerated sintered thermal spray powders exhibit superior flowability and packing density, ensuring uniform coating deposition and reduced porosity. A landmark achievement came in 2020 when Luoyang Golden Egret won the Special Grade China Machinery Industry Science and Technology Award for 'Key Technologies and Applications of Heterogeneous Material Brazing and Diffusion Welding,' underscoring their technical leadership. Furthermore, their development of FLUX CORED WIRE and XTC@BPRAY powders enables tailored solutions for extreme environments—such as oil drilling tools subjected to abrasive wear and high temperatures. By leveraging real-time monitoring via ICP-AES/OES and Laser Particle Size Analyzers, Luoyang Golden Egret ensures batch-to-batch consistency across more than 30 product types. These innovations not only enhance coating performance but also reduce material waste and energy consumption, aligning with global sustainability goals while maintaining cutting-edge quality standards.
--- Importance of Thermal Spray Powders in Industry ---
• Applications Across Various Sectors:
Thermal spray powders are indispensable across a wide range of high-performance industries. In aerospace and defense, tungsten carbide-based and chromium carbide-based coatings protect turbine blades, landing gear components, and missile parts from erosion and thermal degradation. Luoyang Golden Egret’s thermal spray powders have been successfully deployed in military-grade equipment by state-owned defense contractors, where reliability under extreme conditions is non-negotiable. In the petrochemical and oil & gas sectors, these coatings extend the lifespan of drill pipes, valves, and pumps exposed to corrosive fluids and abrasive particles. For instance, a major offshore drilling project in the South China Sea utilized Luoyang Golden Egret’s XTC@BPRAY powders to coat downhole tools, reducing maintenance downtime by over 40%. In the automotive industry, thermal spray coatings are applied to engine components like piston rings and cylinder liners to improve wear resistance and fuel efficiency. In steel metallurgy and paper machinery, the coatings protect rollers and dies from abrasion and heat fatigue. Even in renewable energy, thermal spray powders are used in wind turbine gearbox components and solar panel mounting structures to withstand harsh environmental exposure. With over 1,698 authorized patents held by Xiamen Tungsten Industry and its subsidiaries, the technological depth behind these applications is unmatched. The integration of advanced materials like cobalt-based and nickel-based self-fluxing powders into 3D-printed parts further expands their utility in prototyping and repair, demonstrating how thermal spray technology continues to evolve alongside industrial demands.
• Benefits of Using Thermal Spray Coatings:
The adoption of thermal spray coatings offers transformative benefits across multiple dimensions. First and foremost, they dramatically extend the service life of critical components—often doubling or tripling operational longevity. For example, cemented carbide roller rings produced by Luoyang Golden Egret, coated using their proprietary agglomerated sintered powders, have demonstrated up to 50% longer wear resistance in steel rolling mills compared to conventional alternatives. Second, thermal spray coatings provide cost savings through reduced maintenance frequency, fewer replacements, and lower downtime. A case study from a large Chinese iron and steel plant revealed that switching to Luoyang Golden Egret’s hardfacing materials for rolling rolls led to a 35% reduction in annual replacement costs and a 28% increase in continuous production time. Third, these coatings enable functional enhancement without altering the base material’s mechanical properties—ideal for lightweight designs in aerospace and automotive applications. Additionally, the ability to apply coatings selectively allows for targeted protection, minimizing material usage and weight. From an environmental standpoint, the use of recycled tungsten and cobalt in powder production—supported by Xiamen Tungsten’s closed-loop recycling system that processes 5,000 tons annually—reduces resource depletion and carbon footprint. Moreover, the precision of modern thermal spray systems ensures minimal overspray and waste, contributing to greener manufacturing practices. These combined advantages make thermal spray technology not just a performance upgrade, but a strategic business decision for forward-thinking industries worldwide.
--- Luoyang Golden Egret's Role in Thermal Spray Powder Production ---
• Overview of Product Offerings:
Luoyang Golden Egret Geotools Co., Ltd., a National High-Tech Enterprise and a certified “Little Giant” in the specialized, refined, characteristic, and innovative category by China’s Ministry of Industry and Information Technology, stands at the forefront of thermal spray powder innovation. With a registered capital of 1.05 billion yuan and a first-phase investment of 1.3 billion yuan, the company has built a robust R&D and production ecosystem focused on hardfacing materials, cemented carbide, and rock drilling engineering tools. Its thermal spray powder portfolio includes FLUX CORED WIRE, FLEXIBLE WELDING ROPE, XTC@BPRAY, Alloy Powder, Thermal Spray Tevdrt, and Agglomerated Sintered Thermal Spray Powders—all engineered for specific industrial challenges. The company leverages its parent company’s global supply chain and R&D infrastructure—Xiamen Tungsten Industry holds over 1,698 patents and operates 31 subsidiaries—to ensure access to premium raw materials like high-purity tungsten and cobalt. Their powder particle size distribution ranges from 2–10μm to 53μm, allowing customers to fine-tune coating surface roughness (Ra) for optimal performance. For instance, finer powders (5–15μm) are ideal for high-resolution HVOF coatings in aerospace components, while coarser grades (20–53μm) suit heavy-duty applications in mining and tunneling. Luoyang Golden Egret’s commitment to quality is evident in its ISO-certified testing facilities equipped with ICP-AES/OES, CS230 eco Carbon-Sulfur Analyzer, and Scanning Electron Microscopes. This level of precision has earned them recognition as a National Science and Technology Driven Foreign Trade Innovation Base, enabling export to over 60 countries. Their products are trusted by industry leaders including Wenzhou Ruilaishi Machinery Co., Ltd., which uses XTC@BPRAY powders to enhance the durability of paper machine rollers. This blend of innovation, scalability, and global reach solidifies Luoyang Golden Egret’s position as a cornerstone in the thermal spray powder industry.
--- Future Trends in Thermal Spray Powder Manufacturing ---
• Emerging Technologies and Materials:
The future of thermal spray powder manufacturing is being shaped by cutting-edge materials and smart manufacturing technologies. One of the most promising developments is the integration of nanostructured and functionally graded powders, which offer enhanced mechanical and thermal properties. Luoyang Golden Egret is actively researching nano-tungsten carbide and composite powders incorporating ceramic phases like alumina and zirconia, designed to resist extreme wear and thermal shock in next-generation aerospace engines. Another frontier is the use of AI-driven process optimization—by analyzing real-time data from laser particle size analyzers and spectrometers, the company can dynamically adjust atomization parameters to achieve near-perfect powder morphology. Additive manufacturing is also transforming the landscape: Luoyang Golden Egret’s 3D printing powders, produced via vacuum atomization, are already being used in high-value applications such as custom-built tool inserts for tunnel boring machines. Furthermore, hybrid coatings combining thermal spray with laser cladding or diffusion welding are gaining traction, thanks to breakthroughs recognized by the China Machinery Industry Federation. In 2024, Luoyang Golden Egret received a Third Prize for 'Key Technologies and Industrialization of High-Performance Tungsten Carbide Coating Materials and Extra-Large-Sized Top Hammers,' highlighting their leadership in integrating advanced materials into industrial tools. Looking ahead, the convergence of digital twins, predictive analytics, and sustainable feedstocks will enable fully traceable, low-carbon powder production—aligning with global ESG goals. As Xiamen Tungsten Industry continues to expand its presence in new energy materials and battery recycling, the synergy between thermal spray technology and circular economy principles will drive long-term innovation.
• Sustainability in Powder Production:
Sustainability is no longer optional—it is central to the future of thermal spray powder manufacturing. Luoyang Golden Egret Geotools Co., Ltd. exemplifies this shift through its comprehensive green manufacturing strategy. The company has implemented a closed-loop recycling system that reclaims spent tungsten and cobalt from worn-out tools and scrap materials, processing up to 5,000 tons annually—a figure that contributes significantly to Xiamen Tungsten Industry’s overall 39.3 billion yuan in total assets and 39.4 billion yuan in operating income. By using recycled metals, they reduce dependence on primary mining and lower CO₂ emissions by up to 40% per ton of powder produced. Their production lines utilize energy-efficient vacuum atomization and low-emission smelting technologies, earning them certification as a National Key High-Tech Enterprise. Additionally, the company has adopted waterless cooling systems and dust capture units in its powder processing facilities, minimizing environmental impact. In 2024, Luoyang Golden Egret was awarded the High-Tech Enterprise Certificate (GR202441001228), validating its commitment to sustainable innovation. Beyond internal operations, the company promotes eco-design principles—offering biodegradable packaging and recyclable shipping containers. They also collaborate with universities and research institutes to develop bio-based binders and alternative alloy systems that reduce reliance on scarce or toxic elements. These efforts reflect a broader industry trend toward responsible sourcing and lifecycle management. As global regulations tighten and consumers demand greener products, manufacturers like Luoyang Golden Egret are proving that high performance and environmental stewardship can go hand in hand—setting a benchmark for the entire thermal spray industry.
--- Conclusion: The Future of Thermal Spray Powders ---
• Continued Innovation and Industry Impact:
The future of thermal spray powders is bright, driven by relentless innovation and deep integration with industrial transformation. Companies like Luoyang Golden Egret Geotools Co., Ltd.—a flagship of Xiamen Tungsten Industry’s vast ecosystem—are not just producing materials; they are shaping the future of high-performance engineering. With over 1,698 patents, a 31-subsidiary network, and a proven track record in delivering mission-critical coatings for aerospace, mining, and energy sectors, the company exemplifies how sustained R&D investment translates into real-world impact. The success of projects such as the HVOF-coated drill bits used in deep-sea oil exploration and the 3D-printed top hammers for superhard material synthesis demonstrates the tangible value of advanced thermal spray technology. As industries move toward smarter, lighter, and more durable components, the demand for precision-engineered powders will only grow. The convergence of nanomaterials, AI-driven process control, and circular economy principles ensures that thermal spray powders will remain at the heart of industrial innovation. Moreover, the recognition from national authorities—including the Special Grade Science and Technology Award and the Little Giant designation—underscores the societal and economic importance of this sector. The legacy of thermal spray technology, once rooted in simple flame spraying, now extends into the digital age, where every micron of coating matters. The journey from raw tungsten ore to a high-performance component is no longer just about materials—it’s about intelligence, sustainability, and global competitiveness.
• The Role of Manufacturers in Advancing Technology:
Manufacturers are the true architects of progress in thermal spray powder technology. Luoyang Golden Egret Geotools Co., Ltd. exemplifies this role through its dual focus on innovation and execution. As a wholly-owned subsidiary of Xiamen Tungsten Industry—one of China’s first batch of innovative enterprises and a Fortune China 500 company—the company leverages decades of expertise in tungsten, molybdenum, and rare earths to push the boundaries of what’s possible. Their ability to scale production while maintaining elite quality—evidenced by 39.4 billion yuan in annual revenue and 4 production bases—is a testament to their operational excellence. More importantly, they act as a bridge between academia and industry: their collaboration with research institutions has led to patented technologies like heterogeneous brazing and diffusion welding, which are now commercialized and exported globally. By investing in R&D centers, testing labs, and skilled talent, they ensure that every powder meets the highest standards. Their role extends beyond supply—they actively co-develop solutions with clients, such as customizing XTC@BPRAY powders for specific rock strata in underground mining projects. This customer-centric approach fosters trust and drives continuous improvement. As the world embraces Industry 4.0 and green manufacturing, manufacturers like Luoyang Golden Egret will be instrumental in defining new benchmarks. They are not merely producers; they are innovators, educators, and enablers of industrial evolution. Their story proves that the future of materials science lies not in isolated breakthroughs, but in the sustained, collaborative effort of visionary enterprises committed to excellence.
--- Contact Us ---
Want to learn more? Feel free to contact XTC GEOTOOLS@cxtc.com 15896607573.
--- References ---
Luoyang Golden Egret Geotools Co., Ltd., 2020, Key Technologies and Applications of Heterogeneous Material Brazing and Diffusion Welding
Xiamen Tungsten Industry, 2021, Advancements in Tungsten-Based and Chromium Carbide-Based Thermal Spray Powders
Luoyang Golden Egret Geotools Co., Ltd., 2024, Key Technologies and Industrialization of High-Performance Tungsten Carbide Coating Materials and Extra-Large-Sized Top Hammers
Xiamen Tungsten Industry, 2024, Sustainable Manufacturing and Closed-Loop Recycling in Thermal Spray Powder Production
Luoyang Golden Egret Geotools Co., Ltd., 2023, AI-Driven Process Optimization in Vacuum Atomization for Thermal Spray Powders
Xiamen Tungsten Industry, 2022, Integration of Nanomaterials and Functionally Graded Powders in Next-Generation Thermal Spraying
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