Thermal Spray, Hardfacing & Wear Coatings calculator

Spray Cycle Time per Part Calculator

Estimate per-part spray and elapsed time from deposited mass and qualified feed settings. Enter required deposit mass, calibrated feed and separate cooling and handling pauses.

What this calculator does

  • Estimate per-part spray and elapsed time from deposited mass and qualified feed settings.

Formula used

  • Spray minutes = 100 × Deposit grams ÷ (Feed grams per minute × Efficiency percent)
  • Elapsed minutes = Spray minutes + Cooling minutes + Handling minutes
  • Powder feed grams = 100 × Deposit grams ÷ Efficiency percent

Inputs explained

  • Required Deposit Mass: Coating mass required on one accepted part.
  • Calibrated Powder Feed: Measured powder feed at the qualified operating setting.
  • Measured Deposition Efficiency: Retained mass percentage from comparable part trials.
  • Cooling Pause Time: Total qualified cooling pauses for one part.
  • Handling and Indexing Time: Nonoverlapping loading, unloading and positioning time per part.

How to use the result

  • Best suited to pump sleeve scheduling, coating cycle quotes.
  • Acceleration, interpass constraints and temperature recovery need measured time inputs.

Current U.S. benchmarks

  • Industrial electricity averages 9.77 cents per kWh across the U.S. (EIA, Jul 2026), up 4.7% from a year earlier. Energy-intensive steps carry this directly into unit cost.
  • The producer price index for industrial chemicals stands at 336.006 (BLS, Aug 2026), up 13.3% 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

  • Can powder feed rate replace deposition rate? Only after applying the measured deposition efficiency. Delivered powder and coating retained on the part are different quantities.
  • Should cooling be a percentage of spraying? Use observed or qualified pause minutes here. Cooling time need not scale proportionally with feed time.
  • Does the output permit a faster spray recipe? No. It estimates timing for the settings you enter and does not qualify changes to heat input or coating properties.
  • What if handling overlaps cooling? Enter only the additional handling time outside the cooling interval so elapsed time is not counted twice.

Last reviewed 2026-10-12.