Thermal Spray, Hardfacing & Wear Coatings worked example

Coating Area at 61% spray transfer efficiency: a worked example in thermal spray, hardfacing & wear coatings

This worked example runs the coating area numbers for a tougher week than the baseline: 61% spray transfer efficiency instead of the typical 85%. Coating Area sizes the real spray coverage you must plan for once transfer efficiency — the fraction of powder or wire that actually sticks to the part — is accounted for.

The inputs for this scenario

  • Total surface to be coated: 500 units (held at the documented default)
  • Feedstock consumed per unit area: 0.08 units (held at the documented default)
  • Spray transfer 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 coating area = covered amount × use per unit ÷ transfer efficiency.
  • Required quantity works out to 65.57 sq ft at these inputs, and this is the headline figure for the scenario.
  • Theoretical amount works out to 40 sq ft at these inputs.
  • Loss allowance works out to 25.57 sq ft at these inputs.
  • Efficiency works out to 61 % at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where spray transfer efficiency sits at 85% and the headline result is 47.06 sq ft, this scenario comes in 39.34% above the baseline at 65.57 sq ft.
  • Use it when planning feedstock quantities or spray passes for a coating job, especially with low-efficiency processes or complex geometries. 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 sq ft (headline result)
  • Theoretical amount: 40 sq ft
  • Loss allowance: 25.57 sq ft
  • Efficiency: 61 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Coating Area calculator, set spray transfer efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.