🔧 Thermal Spray Masking Tape Guide

1. Why Use Specialized Masking Tape for Thermal Spray?

Thermal spray processes—including plasma, HVOF, and arc spraying—generate extreme heat, abrasive particles, and high-velocity impacts. Standard masking tapes can degrade, allow leakage, or leave adhesive residue under these conditions.

High-performance thermal spray masking tapes are engineered to:

• Withstand extreme temperatures and abrasive wear
• Provide crisp, clean mask lines
• Leave no adhesive residue
• Resist lifting, chipping, or breakdown during blasting and spraying

2. Types of Masking Tapes

2.1 Single-Ply Fiberglass Tape

Cost-effective and suitable for light-duty spraying or grit blasting. Moderate resistance to heat and abrasion.

2.2 Foil + Fiberglass Composite Tape

Combines aluminum foil and glass cloth for enhanced thermal and abrasion protection. Suitable for more aggressive spray processes. Examples include BTMS Series 190, 179 and 2925-7.

2.3 Multi-Layer Composite Tapes

Constructed with layers such as foil/glass/silicone adhesive. Ideal for HVOF and high-temperature applications. Offers clean edge lines and superior heat and particle shielding.

2.4 Silicone Rubber Tapes (for HVOF)

Rubber-based tapes like MSSA HMVT are highly elastic, heat-resistant, and abrasion-resistant. Designed specifically for HVOF and high-energy spraying.

3. Tape Selection by Spray Type

4. Application Tips

• Surface Prep: Ensure clean, dry, and oil-free surfaces before application.
• Pressure-Sensitive Adhesive Activation: Use a roller or firm pressure after application and allow 12–24 hours for full bond strength.
• Layering Strategy: For clean edges, layer multiple tapes or overlap for added protection.
• Avoid Bridging: Ensure tapes are firmly adhered to avoid chipping or lift-off during spraying.
• Timely Removal: Peel off the tape while the part is still warm to ensure clean removal and sharp mask lines.

5. Recommended Tapes (Examples)

• H7525 Multi-Layer Tape: Glass/Foil/Silicone construction, up to 500°F resistance. Excellent for HVOF and abrasive blasting.
• 2925-7 Foil-Glass Tape: Flexible and high-temperature-resistant, ideal for complex shapes and surfaces.

6. Troubleshooting Common Issues

• Bridging or Lifting: Often caused by poor adhesion or incorrect tape selection. Use higher-performance composite or rubber-based tapes.
• Adhesive Residue: Choose premium tapes that are engineered for clean removal.

7. Summary

To achieve optimal masking results in thermal spray applications:

• Select the right tape based on your process (arc, plasma, HVOF)
• Prepare surfaces properly and allow adhesive time to bond
• Use multilayer or reinforced tapes for high-abrasion or high-temp jobs
• Remove tapes warm for clean mask lines