Definition
A metal-coating process in which a metallic material, fed as wire or powder, is melted in a high-temperature flame and propelled by compressed gas onto a prepared surface, where it solidifies to form a bonded coating. Used in aircraft maintenance and overhaul to build up worn parts to original dimensions or to apply protective or wear-resistant surfaces.
Plain English
A repair technique where metal is melted in a flame and sprayed onto a part, like spray-painting with molten metal. The sprayed metal cools and sticks to the surface, restoring worn material or adding a tough outer layer.
Context Anchor
Seen in aircraft maintenance and repair descriptions, especially when a worn or corroded part needs a new surface coating.
Derivation
From 'flame' (the burning gas that supplies heat) and 'spraying' (dispersing fine droplets through the air). The name describes the process directly: metal is melted by a flame and sprayed onto the work.
Why Pilots Care
Pilots and owners encounter flame-sprayed components in overhauled engines and accessories. Knowing a part has been built up by flame spraying matters for inspection records, dimensional limits, and understanding why a 'worn' part can be returned to service rather than scrapped.
Analogy
It is somewhat like spray painting, but the sprayed material is melted metal or coating material instead of paint.
Intuition Check
Flame spraying does not mean spraying fire onto a part. It means using a flame to melt the coating material, then spraying that material onto the part.
Example Sentence 1
The worn crankshaft journal was restored to its original diameter by flame spraying and then ground to final size.
Example Sentence 2
Flame spraying created a hard, corrosion-resistant coating on the landing gear strut.