How do you calculate this deposition rate?

Divide the affected amount by the total amount. With 8 affected out of 250 total, the rate is 8 ÷ 250 = 3.2%. The calculator then subtracts that from your target to show the gap.

What does the gap to target mean here?

It is the target rate minus the achieved rate. In the example a 95% target against a 3.2% achieved rate leaves a 91.8-point gap, signalling the run is far below where the target says it should be.

Is this the same as mass deposition rate in lb/hr?

No. Mass deposition rate measures coating laid down per unit time and depends on powder feed and gun output. This calculator is a count-based ratio against a target — define your affected and total counts so the rate is meaningful for your context.

What is a good deposition rate target for thermal spray?

It depends on what you are counting. For deposition efficiency, HVOF often runs 50-70% and plasma 40-60%. Set the target to match your metric; the example's 95% target only makes sense if the count represents acceptable or on-spec coverage.

Why is my achieved rate so far below target?

If the achieved rate is tiny relative to target, check whether the affected and total counts are defined consistently — and on the process side, look at standoff distance, powder feed rate, traverse speed, and carrier gas, which all move real deposition outcomes.

Deposition rate vs deposition efficiency?

Deposition rate is how fast or how much coating is achieved; deposition efficiency is the fraction of sprayed material that actually adheres. They trend together but a high rate with low efficiency means you are wasting expensive powder.

Thermal Spray, Hardfacing & Wear Coatings calculator

Deposition Rate Calculator

This Deposition Rate calculator expresses how much of a thermal spray or hardfacing run achieved its intended outcome as a ratio of an affected count to a total count, then measures the shortfall against your target rate. Coating engineers and spray-booth operators running HVOF, plasma, or arc-wire hardfacing on wear-prone components — pump sleeves, valve seats, hydraulic rods — use a rate-and-target view to flag when a process is drifting away from where it should be. Thermal spray is sensitive to standoff, traverse speed, powder feed, and gas flows, so a rate that sits far below target is an early warning that booth parameters or consumables need attention. The gap-to-target number turns a raw count into an actionable delta.

What this calculator does

Calculate deposition rate for thermal spray, hardfacing & wear coatings planning, quoting, troubleshooting, capacity review, or process improvement.
Use it when deposition rate in thermal spray, hardfacing and wear coatings needs a clean rate and gap-to-target you can put on a tier board.
It divides the affected amount by the total amount to produce a rate, then subtracts that rate from your target rate to show the gap in percentage points.

Formula used

Deposition Rate rate = affected amount ÷ total amount
Gap to target = target rate - calculated rate

Inputs explained

Deposition Rate affected amount: undefined
Deposition Rate total amount: undefined
Deposition Rate target rate: undefined

How to use the result

Use it to track a thermal spray run against a target and quantify how far the achieved rate is from where it needs to be.
It is a generic ratio model — it does not by itself measure mass deposition rate in lb/hr or deposition efficiency, so define clearly what your affected and total counts represent before reading the result.

Current U.S. benchmarks

Industrial electricity averages 8.66 cents per kWh across the U.S. (EIA, Apr 2026), up 5.5% from a year earlier. Energy-intensive steps carry this directly into unit cost.
The producer price index for industrial chemicals stands at 344.336 (BLS, May 2026), up 16.1% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The U.S. has 14,543 chemical manufacturing establishments employing about 911,245 workers (Census County Business Patterns, 2023).

Common questions

How do you calculate this deposition rate? Divide the affected amount by the total amount. With 8 affected out of 250 total, the rate is 8 ÷ 250 = 3.2%. The calculator then subtracts that from your target to show the gap.
What does the gap to target mean here? It is the target rate minus the achieved rate. In the example a 95% target against a 3.2% achieved rate leaves a 91.8-point gap, signalling the run is far below where the target says it should be.
Is this the same as mass deposition rate in lb/hr? No. Mass deposition rate measures coating laid down per unit time and depends on powder feed and gun output. This calculator is a count-based ratio against a target — define your affected and total counts so the rate is meaningful for your context.
What is a good deposition rate target for thermal spray? It depends on what you are counting. For deposition efficiency, HVOF often runs 50-70% and plasma 40-60%. Set the target to match your metric; the example's 95% target only makes sense if the count represents acceptable or on-spec coverage.
Why is my achieved rate so far below target? If the achieved rate is tiny relative to target, check whether the affected and total counts are defined consistently — and on the process side, look at standoff distance, powder feed rate, traverse speed, and carrier gas, which all move real deposition outcomes.

Last reviewed 2026-05-12.