Thermal Spray, Hardfacing & Wear Coatings worked example

Bond Coat Usage at 61% powder transfer efficiency: a worked example

This worked example runs the bond coat usage numbers for a tougher week than the baseline: 61% powder transfer efficiency instead of the typical 85%. Before nearly any thermal spray topcoat goes down, a bond coat such as NiAl, NiCrAl or a MCrAlY tie layer is sprayed to key the ceramic or carbide to the substrate.

The inputs for this scenario

  • Total surface area to bond coat: 500 units (held at the documented default)
  • Bond coat consumption per unit area: 0.08 units (held at the documented default)
  • Powder transfer (deposit) efficiency: 61 % (the input this scenario stresses; the baseline uses 85)

Working through the calculation

  • The calculation starts from the formula this tool documents: Required bond coat usage = covered amount × use per unit ÷ transfer efficiency.
  • Required quantity works out to 65.57 units at these inputs, and this is the headline figure for the scenario.
  • Theoretical amount works out to 40 units at these inputs.
  • Loss allowance works out to 25.57 units at these inputs.
  • Efficiency works out to 61 % at these inputs.

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 39.34% above the baseline at 65.57 units.
  • Use it when ordering powder for a job, costing a coating quote, or setting a reorder point for a bond coat alloy you run regularly. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Required quantity: 65.57 units (headline result)
  • Theoretical amount: 40 units
  • Loss allowance: 25.57 units
  • Efficiency: 61 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Bond Coat Usage calculator, set powder transfer efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.