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Combustion Flame Spray

Combustion Flame Spray Coating (also known as traditional thermal spray coating) involves using a combustible gas as a heat source to melt feedstock in the form of a powder, wire, or rod and to propel the melted droplets at the component surface. The droplets impact the surface and thus the coating is formed. Masking for flame spray coatings can be challenging as heat is a factor.

Flame spray coatings are commonly used in industries such as Aviation/Aerospace, Energy (Industrial Gas Turbines), Semiconductor (Parts Cleaning), and General Industrial applications. Common applications abradable coatings, wear coatings, and corrosion resistance.

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Product Recommendations – Combustion Flame Spray

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6605-07D – Basic single sided glass cloth tape suitable for non-critical Abrasive Blasting masking. A good choice for single layer secondary masking.

6615-07 – Double sided fiberglass tape, 7 mil,  complete with silicone adhesive on both sides. Tape usually comes with a crepe paper liner. This tape offers exceptional conformability and strong adhesion metal (and face-to-back).

6615-12 – Thicker double sided fiberglass tape, 12 mil – good for single layer plasma spray masking

6625-07 – Aluminum foil flame spray masking tape, 7 mil (with 1 mil foil)

6625-09 – Aluminum foil flame spray masking tape, 9 mil (with 2 mil foil)

6625-11 – Aluminum foil flame spray masking tape, 11 mil (with 4 mil foil)

6525-08 All-purpose Abrasive Blasting masking tape. Tape is suitable for grit blast and air plasma applications. Construction is silicone rubber coated fiberglass complete with silicone adhesive.

6525-16 – Double Layered masking tape. Double Layer allows for single layer application for each job. In cases where 2 layers of standard tapes are required, the 6525-16 can reduce masking times by 50%.

7102W – Silicone coated fiberglass fabric, 10 mil. This fabric can be used as a light duty reusable masking blanket capable of protecting against overspray.

7322W – All Purpose thermal spray masking blanket constructed of silicone coated fiberglass fabric. This fabric is ideal for secondary masking of large components for most spray styles.

7422W – Heavy silicone coated fiberglass fabric for more demanding jobs requiring protection of large surfaces. This fabric is more abrasive resistant and more suitable for primary masking jobs (as well as secondary).


  • TacMold (A2023-A / A2023-B) masking compound is a 2 part silicone putty which is designed to withstand all forms of thermal spray including GF-HVOF and LF-HVOF. This putty is intended to assist with masking holes or complicated intricate profiles. In some cases, the compound is reusable.
  • TacBloc – A soft, conformable, putty-like material for masking holes, grooves, key slots or any unique configuration. Unlike TacMold, TacBloc is formulated to adhere to metal in areas where anchorage is not possible. TacBloc is good for all forms of thermal spray.

Our How to Guide explains the best way to maximise the advantages of our TacMold & TacBloc Masking Compounds. Please log in or register to download it.