How to choose.
Thermal spray processes hurl molten or semi-molten particles at the workpiece — conditions that vaporise paper and melt polymer films on contact. Aluminum foil tape masks these processes because metal foil reflects and conducts the heat away while physically shrugging off particle impact, keeping a sharp coating boundary on the part underneath.
Where foil tape is specified
Aerospace component coating and turbine blade repair are the signature applications: masking the areas of a blade or housing that must stay coating-free during plasma or HVOF spraying. General heavy industry uses the same tapes wherever flame-spray build-up or hard-facing needs a defined edge.
Matching tape to process
Not all thermal spray is equally brutal. Full plasma and HVOF work calls for heavy foil grades, sometimes with glass-cloth reinforcement; lower-energy flame spray can use lighter foil constructions at lower cost. Specify the spray process, particle material and standoff, and we will match the construction rather than default to the heaviest — or worse, an inadequate — grade.
Application notes
Surface prep matters more here than anywhere: degrease thoroughly, press edges hard, and double-layer at the spray boundary where impact is most intense. Foil tape is single-use; remove after spraying while the part is warm for the cleanest edge.
