Arc spray (sometimes referred to as twin wire arc spray) is a process that uses an electric arc to melt wires. The molten metal is then atomised with compressed air to create a spray stream that applies the coating onto the surface being sprayed. The resulting coating offers exceptional corrosion resistance, thermal protection, and wear resistance. Anti-corrosion or engineering coatings can be applied by arc spray and changing between the two is quite simple. Our arc spray systems are easy to operate with clear controls and reliable performance. With our focus on efficiency, you can expect quick coatins with minimal material waste, making it not just a powerful choice, but an economical one too.
Metallisation has a full range of arc spray systems for hand-held and fully automatic / robotic applications. See the full range below:
Arc spraying is a process whereby two wires (hence a common term for the process is Twin Wire Arc Spray), are fed into the pistol and electrically charged, one positive and one negative. The wires are forced together and form an electric arc, melting the wire. Compressed air, passing through a nozzle, atomises the molten metal and sprays it onto the workpiece.
There are three methods of wire feeding, push, pull and push/pull. The higher the current rating of the system, e.g. 350A, 700A etc., the higher the spray rate.
Arc spraying is typically used in scenarios where corrosion protection, wear resistance, thermal insulation, or electrical conductivity are required. Arc spraying is particularly useful for applications in industries such as aerospace, automotive, marine, and manufacturing, where durable and high-performance coatings are essential for extending the lifespan and improving the performance of components and structures.
High deposition rates and easy to use equipment make arc spraying an attractive thermal spray solution.
On a typical handheld arc spray pistol, there is a trigger to start the wire feed. The head is held around 150mm from the substrate and moved sideways to deposit a consistent coating thickness in a similar way to paint spraying.
Different Personal Protective Equipment to paint spray is needed for the arc spray process as UV light and metal fumes are produced.
Arc spray equipment requires a 3 phase electrical power supply and a compressed air supply.
Zinc is widely used in arc spraying for anti-corrosion protection and various other applications. When zinc is thermally sprayed onto a surface, it acts as a sacrificial layer, protecting the underlying material. This coating is particularly effective in environments with a pH of 5 or higher, extending the time before the first maintenance is needed. Zinc coating can also be combined with sealers and paints. Metallisation Ltd offers a full range of zinc wire in all sizes.
