Thermal Spraying Processes

Wire Arc Spray


This form of thermal spraying uses wire material as a feed stock. An electric arc is used as the heat source. As the wires are fed towards each other, an electric arc is struck between the wires creating a temperature of around 4,000°C.

This temperature causes the tips of the wire to melt and once molten state, a stream of compressed air or inert gas is used to atomise and accelerate the feed metal towards the substrate.

Characteristics of Wire Arc Spray :

Material Form Wire
Heat Source Electric Arc
Flame Temperature (°C) 3600 to 4000
Particle Velocity (m/sec) < 300
Porosity (%) 10 to 15
Coating Adhesion (MPa) 28 to 42

Advantages :

  • Coatings with good characteristics can be achieved
  • Two different wires can be used simultaneously to produce a pseudo alloy
  • Cored wires are also available producing coatings with unique properties
  • Applying coating to large areas is easier by this process
  • Used for dimensional restoration due to higher deposit efficiency

Disadvantages :

  • Coatings achieved are not dense and have porosity of up to 15%
  • Good suface preparation is very essential for good bond strength
  • Coatings limited to materials available in wire form with low melting tempertaure


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