Thermal Spray, Hardfacing & Wear Coatings worked example

Gas Consumption at 61% deposit and transfer efficiency: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop deposit and transfer efficiency to 61%, then walk the calculation through step by step. Gas Consumption converts the area you need to coat into the actual quantity of consumable — powder or process gas — you must load, after accounting for the deposit efficiency that every thermal spray process loses to overspray.

The inputs for this scenario

  • Total surface area to coat: 500 units (held at the documented default)
  • Powder / gas draw per unit area: 0.08 units (held at the documented default)
  • Deposit / 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 gas consumption = 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 deposit and 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.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to deposit and transfer efficiency, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. Deposit efficiency shifts with standoff, spray angle, part geometry and powder — a single figure is an average, and edges or complex shapes lose more.

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 Gas Consumption calculator, set deposit and transfer efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.