Thermal Spray Operator

This position supports the repair and manufacturing of critical turbine parts by applying protective coatings that enhance wear resistance, corrosion protection, and thermal barrier performance. The ideal candidate will have experience working with industrial gas turbine components and thermal spray equipment in a manufacturing or repair environment. 

Key Responsibilities:

Thermal Spray Operation: 

• Follow Work Instructions, Load Programs into the ABB Robots, Operate and maintain HVOF & PLASMA spray equipment, including HVOF (High Velocity Oxygen Fuel) guns, PLASMA guns, and spray systems. 
• Ensure that the equipment is calibrated, configured, and ready for coating applications in accordance with specified engineering specifications.  

Preparing Surfaces: 

• Properly prepare surfaces to be coated by cleaning, Masking, Polymer Application (DYMAX), grit blasting, ensuring the surface is free from contaminants, ensuring optimal coating adhesion, and deburring the coating on non-coated areas.  

Material Preparation: 

• Handle and prepare thermal spray materials, including powders to be fed into the HVOF & PLASMA gun for the coating process.   

Coating Application: 

• Skillfully apply HVOF & PLASMA thermal spray coatings on various substrates while adhering to precise parameters such as gases, powder feed, and Coating Thickness.  
• Verify coating thickness, surface finish, and coating quality using approved inspection processes. 

Quality Control: 

• Read, interpret, and follow all engineering drawings, coating specifications, process sheets, and technical instructions. 
• Continuously monitor the spray process to ensure it meets specifications. This often involves using precision tools like calipers and micrometers to measure coating thickness and other parameters.  
• Continuously perform and track routine equipment maintenance, including all required preventive maintenance scheduling, proper troubleshooting, and necessary process adjustments to ensure continuous high-quality coatings. 

Safety Compliance: 

• Adhere to all established safety initiatives, including but not limited to proper PPE usage, maintaining good housekeeping standards throughout the department and work facility. 
• Personally observe safety and security procedures and proper use of equipment and material and actively promote safety processes.  

Documentation: 

• Accurately document and record all spray and coating processes and data. Track and maintain all spray and coating material usage, coating thicknesses, and other quality-control checks.
• Proactively collaborate with engineering and the production team to resolve any process gaps or issues. 
• Support and adhere to all continuous improvement initiatives to enhance and improve efficiency, productivity, quality, and process reliability. 
• Perform other related tasks assigned by management 

• High school diploma or GED required; technical or vocational training preferred.
• Minimum 3–5 years of experience and knowledge operating plasma spray or thermal spray coating equipment.
• 3- 5 years of experience coating industrial gas turbine components, including but not limited to Turbine blades, Vanes, Combustion components, Transition pieces, Shrouds, and compressor components.  
• Knowledge of thermal spray processes, including plasma spray, HVOF, and bond coat applications.
•  Ability to read and interpret blueprints, technical drawings, and process specifications.
• Must be able to perform basic mathematical arithmetic for proper measurements, calculations, and defining and interpreting technical drawings. 
• Familiarity with coating thickness measurement equipment and inspection techniques.
•  Strong attention to detail and commitment to quality standards.
• Must be available to work days, nights, weekends, and holidays as business requires.