Thermal Spray, Hardfacing & Wear Coatings worked example

Gas Consumption at 98% deposit and transfer efficiency: a worked example

Push deposit and transfer efficiency up to 98% and the picture changes. This example computes every intermediate figure at that operating point. Use it when gas consumption 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 coat: 500 units (unchanged)
  • Powder / gas draw per unit area: 0.08 units (unchanged)
  • Deposit / transfer efficiency: 98 % (raised for this scenario; the documented default is 85)

Working through the calculation

  • Applying the documented formula (Required gas consumption = 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 deposit and 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 scales coated area by the per-unit draw and divides by transfer efficiency to get required consumable, then reports the loss allowance versus the theoretical amount. 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 Gas Consumption calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.