Thermal Spray, Hardfacing & Wear Coatings worked example

Bond Coat Usage at 98% powder transfer efficiency: a worked example

Push powder transfer efficiency up to 98% and the picture changes. This example computes every intermediate figure at that operating point. Use it when bond coat usage in thermal spray, hardfacing and wear coatings needs a buy quantity for the next thermal spray, hardfacing and wear coatings run and you do not want to short the line.

The inputs for this scenario

  • Total surface area to bond coat: 500 units (unchanged)
  • Bond coat consumption per unit area: 0.08 units (unchanged)
  • Powder transfer (deposit) efficiency: 98 % (raised for this scenario; the documented default is 85)

Working through the calculation

  • Applying the documented formula (Required bond coat usage = covered amount × use per unit ÷ transfer efficiency) to the inputs above produces each figure below.
  • At this operating point the engine returns 40.82 units for required quantity, the number this scenario is built around.
  • At this operating point the engine returns 40 units for theoretical amount.
  • At this operating point the engine returns 0.82 units for loss allowance.
  • At this operating point the engine returns 98 % for efficiency.

How this compares with the baseline

  • Against the tool's baseline example, where powder transfer efficiency sits at 85% and the headline result is 47.06 units, this scenario comes in 13.27% below the baseline at 40.82 units.
  • It computes the actual bond coat powder required by dividing theoretical demand (area x consumption per unit) by transfer efficiency, and reports the loss allowance above theoretical. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Required quantity: 40.82 units (headline result)
  • Theoretical amount: 40 units
  • Loss allowance: 0.82 units
  • Efficiency: 98 %

Run it with your numbers

  • Every input above is editable in the live Bond Coat Usage calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.