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Peter Ambuehl is back for an open and in-depth discussion on Thermal Spray Technology. After our previous interview series on thermal spray coatings, Peter returns for an interactive Q&A session, answering real technical questions and sharing hands-on experience from decades in coating and surface engineering. In this episode, we discuss thermal spray fundamentals, process selection, productivity, coating quality, and real industrial decision-making, including comparisons with laser cladding. This video is highly relevant for: Coating engineers Thermal spray specialists Maintenance & repair professionals OEMs and job shops Anyone working with HVOF, plasma spray, flame spray, wire & powder systems ⏱ Discussion Timeline & Key Topics 00:00 – Introduction 02:00 – Gun development: how and why designs evolved 06:00 – Wire deposition efficiency & electrical conductivity 07:00 – “As good as needed”: maintenance intervals vs feedrate 10:00 – Productivity vs porosity: finding the right compromise 12:20 – Customer relationships & supporting with know-how 14:00 – How customers profit from thermal spray coatings 17:20 – 6 practical tips from Peter for thermal spray success 19:15 – Hard chrome replacement 22:05 – Self-fluxing alloys & flame spray applications 25:00 – Do we really need high hardness? 27:17 – Adhesion mechanisms of thermal spray coatings ➡️ Flame spray vs plasma vs HVOF & crankshaft repair 31:50 – Laser cladding vs thermal spray for rotational parts 33:00 – Cost considerations: aluminum wire & powder guns 36:40 – Advantages of powder over wire 38:15 – Thermal limits of thermal spray processes ➡️ Coating thickness, residual stresses & crack formation 🔗 Previous Interview Series with Peter Ambuehl ▶️ Video 1: • Thermal Spraying Explained – Arc & Flame S... ▶️ Video 2: • Why HVOF Is the Workhorse of Thermal Spray... ▶️ Video 3: • Plasma Spray: The Most Flexible Thermal Sp... If you work with thermal spray coatings, repair technologies, surface engineering, or laser cladding, this discussion will give you practical insight beyond textbooks. 💬 Leave your questions in the comments — future Q&A sessions are coming.