Thermal spray, metal spray, and metalizing are different names for the same generic process whereby a material is heated and accelerated towards a prepared substrate in a molten or semi-molten condition. The acceleration is through a gas stream heated either by combustion or arcing. The particles bond to the substrate mechanically and solidify immediately upon impact to form a dense protective coating. Build-up of several layers of these particles form a protective coating on the sprayed area. It is important to remember that a thermal coating offers a protection layer and not additional base metal.

BTS uses state-of-the-art, high velocity systems to apply coatings. High velocity systems produce denser and better bonded coatings than conventional arc or flame spray technology. As a result coatings applied by high velocity technology show better field performance. The two primary systems used by BTS are the Excalibur 4000 HVOF system that uses powder as feedstock and the Excalibur 2000 HVCC system that uses wire as feedstock.