Process Description
The Electric Arc Wire Spray process uses two metallic wires, usually of the same composition, as the coating feedstock. The two wires are electrically charged with opposing polarity and are fed into the arc gun at matched, controlled speeds. When the wires are brought together at the contact point, the opposing charges on the wires create enough heat to continuously melt the tips of the wires. Compressed air is used to atomize the now molten material and accelerate it onto the workpiece surface to form the coating.

Schematic cross-section of a typical electric arc wire spray gun

In electric arc wire spray, the weight of coating that can be deposited per unit of time is a function of the electrical power (amperage) of the system and the density and melting point of the wire. Depending on the columnar strength of the wire, ‘push’, ‘pull’ or ‘push/pull’ mechanisms can be used to feed the wire at a constant rate.

Key components of electric arc wire spray system

Features of the Electric Arc Wire Spray Process:
• Applies a range of metallic alloys and pure metals for restoration, corrosion coatings and other purposes in solid wire or cored (filled) wire forms
• Systems are compact and self-contained
• Excellent portability for on-site coatings
• Does not require any process water or gases except compressed air
• High spray rates
• Produces coatings that are easily machined
• Masking of areas that should not be coated is possible
• Coating of internal geometries is possible
• Very simple to operate and maintain