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Thermal Spray Coating Engineer information

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$75.5K

$100.3K

$122.5K

How much do thermal spray coating engineer jobs pay per year?

As of Sep 9, 2026, the average yearly pay for thermal spray coating engineer in the United States is $100,319.00, according to ZipRecruiter salary data. Most workers in this role earn between $88,500.00 and $109,500.00 per year, depending on experience, location, and employer.

What does a thermal spray coating engineer do?

A Thermal Spray Coating Engineer is responsible for designing, developing, and overseeing the application of protective coatings to surfaces using thermal spray processes. These coatings are typically applied to improve wear resistance, prevent corrosion, or restore dimensions to components in industries such as aerospace, automotive, and energy. The engineer selects appropriate materials and equipment, optimizes process parameters, and ensures that coatings meet quality and safety standards. They may also be involved in troubleshooting, research, and development of new coating technologies.

What are the key skills and qualifications needed to thrive as a thermal spray coating engineer?

To thrive as a Thermal Spray Coating Engineer, you need a solid background in materials science, mechanical engineering, and surface engineering, often supported by a relevant engineering degree. Familiarity with thermal spray equipment, process controls, and industry standards such as ISO or ASME, along with certifications like AWS CWI or NACE, is highly valuable. Strong analytical thinking, attention to detail, and effective communication skills help ensure quality results and collaboration with cross-functional teams. These competencies are crucial for developing durable coatings, optimizing processes, and meeting safety and performance specifications in demanding industrial environments.

What are some typical challenges faced by thermal spray coating engineers in maintaining coating quality and consistency?

Thermal Spray Coating Engineers often encounter challenges related to ensuring coating uniformity, adhesion, and thickness, especially when working with complex geometries or varying substrate materials. Controlling process parameters such as spray distance, temperature, and material feed rates is critical to achieving consistent results. Additionally, they must troubleshoot equipment issues and adapt to evolving customer specifications, all while adhering to strict safety and environmental standards. Collaboration with quality assurance teams and production staff is essential to resolve issues quickly and maintain high-quality outputs.

What is the difference between Thermal Spray Coating Engineer vs Surface Coating Technician?

AspectThermal Spray Coating EngineerSurface Coating Technician
CredentialsBachelor's degree in engineering or materials science, certifications in thermal spray processesHigh school diploma or technical training, certifications in coating application
Work EnvironmentDesigning processes, overseeing coating applications, testing materials in labs or industrial settingsApplying coatings on parts in manufacturing or maintenance settings
Industry UsageResearch, development, and quality control in aerospace, automotive, or industrial sectorsProduction and maintenance in manufacturing plants or repair shops

The main difference is that Thermal Spray Coating Engineers focus on designing and improving coating processes, while Surface Coating Technicians perform the actual application of coatings. Engineers typically require higher education and work in more analytical roles, whereas technicians focus on hands-on application and maintenance tasks.

What are popular job titles related to Thermal Spray Coating Engineer jobs?

For Thermal Spray Coating Engineer jobs, the most frequently searched job titles are:

Infographic showing various Thermal Spray Coating Engineer job openings in the United States as of September 2026, with employment types broken down into 1% Internship, 92% Full Time, 3% Part Time, and 4% Contract. Highlights an 85% Physical, 4% Hybrid, and 11% Remote job distribution, with an average salary of $100,319 per year, or $48.2 per hour.

Thermal Spray Operator

Springfield, NJ • On-site

Cincinnati Thermal Spray, Inc
Manufacturing • 201 - 500 employees
Learn more about Cincinnati Thermal Spray, Incexternal

Full-time

Re-posted 17 days ago

Job description

SUMMARY:
CTS is hiring focused and detail-oriented Thermal Spray Operator for our Springfield, NJ location. Thermal Spray Operators play an integral part in the thermal spray coating process- so much so that it's included in our company name!
DUTIES & RESPONSIBILITIES:
  • Performing production functions and obtaining certification for Combustion, Plasma, Hyper velocity oxy-fuel (HVOF), and/or Electric Arc thermal spray all while being safe in the process!
  • Following technical documents, drawings, blueprints, and/or plans to perform these functions.
  • Performs other tasks as necessary.

REQUIREMENTS:
  • 18+ years of age
  • High School Diploma or GED
  • U.S. Person pursuant to ITAR/EAR
  • Successfully pass background check and drug screening
  • Technical and/or mechanical aptitude with the ability to problem-solve and always work with integrity.

Plus:
  • 1+ year of experience in thermal spray

Apply