Compare a defined coating system
Hard chrome and thermal spray are process families, not a single pair of interchangeable coatings. Compare the specified deposit or spray material, substrate, working conditions and finished dimensions.
Assess performance for the application
Review wear, corrosion exposure, adhesion, required finish and repair allowance. No process is universally superior, cheaper or longer lasting. Use relevant test results and the customer specification rather than generic rankings.
Include the complete process cost
Include preparation, masking, deposition, final grinding, inspection and downtime. Access to a surface and permitted heat exposure can affect the route; ask the supplier to confirm these for the actual part.
Evaluate health and environmental controls
An alternative process is not automatically non-toxic or free of hazards. Review its material safety information, emissions, exposure controls, waste treatment and energy requirements before comparing environmental performance.