Vol423,
"Spray Welding" is a generic term that refers to at least two different processes that use metal powder to build up a worn suface. Basically, the powder is melted into individual droplets in an electric arc or oxy-acetylene flame and propelled at high velocity onto the surface where is bonds to the surface and to itself. It is commonly used in industrial repair shops to build up worn surfaces such as bearing fits on shafts, etc. After the metal is applied,, the repair is machined to the desired size. It is fast and does not heat the repaired area as much as welding. Properly done, the bond to the base material is quite good although not as good as a conventional weld.
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