Electric arc wire spraying offers you excellent portability for on-site coatings. It covers applications for welded tube seams, piston rings, capacitors, varistors, boiler walls, and large infrastructures. It uses only electricity and atomized air to melt metallic alloy and pure metal wires.
Process description
For the electric arc wire spray process, we use 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 we bring the wires together at the contact point, the opposing charges on the wires create enough heat to continuously melt the tips of the wires. We use compressed air to atomize the now molten material and accelerate it onto the workpiece surface to form the coating.
Process basics
| Heat source | Plasma Arc |
| Material | Wire |
| Arc temperature | Approx. 4,000 °C |
| Particle velocity | Approx. 150 m/s |
| Spray performance | 15 – 3,300 g/min |
Key characteristics
- Excellent portability for on-site coatings
- Does not require any process water or gasses except compressed air
- High spray rates
Our combustion wire flame spray services include anti-corrosion coatings and dimensional surface restoration. Metal-based wires are used in-shop or on-site for coating large steel structures, chemical and petroleum tanks, and marine applications.
Process description
We continually feed the spray material in wire form into a fuel gas-oxygen flame where it is melted by the heat of that combustion. Compressed air surrounds the flame and atomizes the molten tip of the wire. This accelerates the spray of molten particles towards the prepared workpiece surface. Combustion wire spray is a common choice for machine element repair and corrosion coatings. You have the option of either hard (higher melt temperature) or soft (lower melt temperature) wires.
Process basics
| Heat source | Fuel and Oxygen |
| Material | Wire (Metal) |
| Flame temperature | Approx. 3,100 °C |
| Particle velocity | Up to 200 m/s |
| Spray performance | 15 – 1,400 g/min |
Key characteristics
- Portable for on-site coatings
- High spray rates with low gas consumption
