Thermal spray gun with fan spray

A thermal spray gun includes a first burner (40) for producing a first fan-shaped flame, a second burner (40') for producing a second fa-shaped flame parallel to the first in sufficient proximity to commingle into a combined fan-shaped flame. Powder is dispersed into a fan-shaped powder spray entrained between the first and second flames. The gun body has a fan-shaped powder chamber with an open side opening forwardly from the gun body between the first flame and the second flame and with an apex lcoation opposite the open side. First and second powder ducts each terminate at the apex location with a common axis perpendicular to the fan-shaped chamber such as to mutually impinge the first and second powder streams into a combined powder stream dispersing through the fan-shaped powder chamber into the fan-shaped powder spray. A first fan-shaped air flow is introduced between the first flame and the fan-shaped air flow is introduced between the first flame and the fan-shaped powder spray, and a second fan-shaped air flow is introduced between the second flame and the fan-shaped powder spray.