The use of coatings for the control of wear and corrosion is well known. However, coatings and other surface solutions offered by Sulzer Metco are also used in a surprising number of applications for dimensional control, restoration and for applications where a specific surface profile or contour is required. While many coatings can be used in their "as-sprayed" condition, a large number of coatings can be ground or machined to very tight dimensional tolerances and to a wide variety of surface finishes to suit application requirements.

Thermal spray and weld overlay coatings are effectively applied for dimensional restoration of worn or falsely machined components. The rebuilt areas can be machined to tight tolerances, with the required surface finish. While the coatings used for mismachined applications are usually of a composition similar to the substrate they are applied to, those used for dimensional restoration are most often designed to help prevent further damage through the application of a more wear resistant material.

Thin films and plasma nitriding are applied to finished components and do not require machining after application; however, post-processing polishing may be performed.

Specific thermal spray coatings and honeycombs are used for clearance control in rotating equipment.