Do you think your thermal spray consumables SHOULD or COULD last longer?
Consider first the copper that the thermal spray consumables are made from.
There are thousands of copper alloys that can affect the life of a thermal spray consumable. The copper can be pure copper or a copper/tungsten alloy.
Each manufacture of consumables chooses the type of copper they wish to use. For instance, the JP5000 HVOF barrels are typically made of C145 copper (tellurium) with a Rockwell B harness of 48 and ...