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Center for Thermal Spray Research at the State University of New York at Stony Brook
Twin Wire Arc Thermal Spray Process

The Arc Spray Process utilizes a pair of electrically conductive wires, which are melted by means of an electric arc. The molten material is then atomized by compressed air and propelled onto a substrate surface. The impacting molten particles rapidly solidify on the substrate to form a coating. This process is referred to as cold process (relative to the substrate material being coated) as the substrate temperature can be kept low during processing avoiding damage, metallurgical changes and distortion to the substrate material.

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The main applications are anti-corrosion coatings of zinc and aluminum and machine element work on large components.

Advantages
  • Denser and stronger than equivalent combustion spray coatings.
  • Large areas are easily coated due to high spray rates.
  • Normal>Efficient and economical for high production rates.

Limitations
  • Only electrically conductive wires can be sprayed.
  • Separate heating source required when substrate pre-heating is required.


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