Thermal plasma spray is used for applications such as chrome plating and anti-corrosion coatings, sometimes in high-risk environments. It is not inherently dangerous, but knowing the health and safety implications can help you follow the correct procedures and minimise risk.
What is thermal spraying?
Thermal spraying is a way of depositing particles of ceramic or metal material on a substrate. Thermal plasma spray is used primarily in engineering, biomedical, and electronics applications.
Thermal plasma spray risks
Identifying thermal plasma spray risks is the first step in keeping your workplace safe:
Explosion
Explosion is the primary safety risk with plasma spray. Hydrogen is highly flammable, and a hydrogen fire is almost invisible. Fire-retardant and friction-free PPE are essential for working with plasma spray gases.
Dust and fumes
Thermal plasma spray can produce dangerous dust and fumes. Extraction equipment and using breathing masks with filters can reduce these effects.
UV radiation
UV radiation is another potential hazard of thermal plasma spray. UV can cause sunburn and changes in skin cell growth. Skin may appear prematurely aged, and operators may have a higher skin cancer risk. The skin should be covered entirely before using thermal spraying equipment.
Electricity
The electricity supply for thermal plasma spray equipment isn’t considered dangerous; however, the spraying equipment is generally fed from a higher voltage power supply, which can be hazardous.
General hazards
Heat and glare present a general hazard with any thermal spraying equipment. Potential risks are multiplied when working at height or in a confined space. Anyone who is using thermal plasma spray equipment should receive appropriate safety training to make them aware of possible hazards.
Practising thermal spray safety
The HSE Executive has extensive resources on thermal spraying safety Professional plasma spray teams, such as those at https://www.poeton.co.uk/advanced-treatments/apticote-800-thermal-plasma-spray, will be aware of the risks and have safety measures in place to mitigate them. Training, PPE, risk assessments, and safe working practices should all be put in place to keep employees safe.
With the right precautions in place, thermal spraying is an excellent way to apply coatings.
