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In manufacturing, thermal spray technology encompasses a group of coating processes that provide functional surfaces to improve the performance of the components and protect them from corrosion, wear, heat and other failings. Many types and forms of feedstock can be thermal sprayed, and each requires different process conditions and life cycle preparations. The required thermal energy is generated by a chemical (combustion) or electrical (plasma/or arc) energy source. Due to high inefficiencies associated with energy and material consumption in this process, a comprehensive resources used analysis for a sustainable improvement has always been promising. This study aims to identify and compare the influence of using different forms of feedstock (powder, suspension) as well as energy sources (combustion, plasma) on efficiency and effectiveness of energy conversion and resources consumption for different thermal spray processes based on energy and exergy analysis. Exergy destruction ratio and effectiveness efficiency are used to evaluate the energy conversion efficiency. The degree of perfection and degree of energy ratio are applied to account for the intensity of resources consumption (energy or material) in thermal spray processes. It is indicated that high velocity suspension flame spray has the lowest effectiveness efficiency and the highest exergy destruction compared to other thermal spray processes. For resource accounting purposes, in general, suspension thermal spray showed the lower degree of perfection and accordingly the higher inefficiency of resources used compared to powder thermal spray.

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