Thermal Spray Operator

Mechanical-Dynamics-; Minnesota; On-site; USD 55,000 - 75,000; Full time

Job summary

Mechanical-Dynamics- is seeking an experienced technician to support repair and manufacturing of turbine parts by applying protective thermal spray coatings. Duties include loading programs into ABB robots, operating HVOF and plasma spray systems, and ensuring coating thickness per specifications.

The role requires 3–5 years in plasma/thermal spray, familiarity with turbine components, reading blueprints, and proper use of measurement tools. Shifts include days/nights and possible weekends.

Qualifications

• High school diploma or GED required; technical or vocational training preferred.
• ,
• Minimum 3–5 years of experience operating plasma spray or thermal spray equipment.
• 3–5 years of experience coating industrial gas turbine components (turbine blades, vanes, combustion parts, transition pieces, shrouds).
• Knowledge of plasma, HVOF, and bond coat processes.
• Ability to read blueprints, drawings, and process specs.
• Ability to perform basic arithmetic for measurements.

Responsibilities

• Operate and maintain HVOF and plasma spray equipment per work instructions.
• Prepare surfaces via cleaning, masking, grit blasting, and coating adhesion checks.
• Handle and prepare thermal spray materials for coating processes.
• Apply coatings to various substrates following specified parameters and thickness requirements.
• Verify coating thickness and surface finish with approved inspection methods.
• Document coating processes and data; support continuous improvement.

Skills

Plasma spray

Thermal spray coating

HVOF

Blueprints & drawings

Measurement tools

Quality standards

Basic arithmetic

Shifts availability

Education

High school diploma or GED

Technical/vocational training (preferred)

Tools

HVOF spray equipment

Plasma spray equipment

Calipers

Micrometers

Grit blasting equipment

Job description

Description

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

Requirements

• 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 toTurbine 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.