Arc Spray

What is Arc Spray?

Arc spray (also known as twin wire arc spray or thermal arc spray) is a method of melting wires using an electric arc. Arc spray systems are available as "push" or "push/pull" systems and are often believed to be simple to operate and automate. A "push" system pushes the wire to the gun, is lighter and easier to handle than a "push/pull" gun, and is typically employed in engineering applications when hard engineering wires are utilised and the distance between the machine and the gun is small (5 metres). When a longer distance between the gun and the machine is required, "push/pull" methods are utilised, which are common in anti-corrosion work involving soft wires (zinc and aluminium). The systems either push or pull each other.

Arc Spray coatings can be sprayed to a wide range of materials, including metal, wood, polystyrene, plastic, glass, paper, ceramics, and even chocolate (for demonstration reasons only), and can be used in a wide range of artistic applications. Arc sprayed coatings also give the optimum surface for any type of top-coat, from painting to powder-coating, in any colour! When it comes to spraying, the Arc Spray technique is noted for its minimal heat input. When it comes to thermally sensitive substrates, arc spray is advantageous due to the low heating of the substrate. Component distortion is also reduced due to the minimal heat input.

Features of Arc Spray

• Wire diameters range from 1.6mm to 4.76mm (depending on which model is used).
• In comparison to plasma or HVOF, there is a low power usage.
• Operation is as simple as pushing a button.
• When it comes to thermally sensitive substrates, arc spray is advantageous due to the low heating of the substrate. Capacitors and electronic components, for example.
• To allow the coating qualities to match the application needs, a variety of porosity levels can be accomplished.
• Because arc spray doesn't involve combustion gases or create a high-energy plasma, it poses less health and safety issues than other thermal spray methods.
• In comparison to HVOF spraying, the arc spray technique offers lower costs and higher throughput coatings.
• Applications in engineering
• Applications for anti-corrosion.
• Applications for surface modification.
• Applications that are decorative.
• Operation can be done manually or automatically.
• Option for robotic operation is available.
• The Push/Pull synchronous drive provides exceptional wire feed dependability of up to 20 metres.
• Closed loop current regulation enables consistent spraying and ease of use.

Arc Spray Application

• Coatings for aerospace engineering.
• Panels with an Al-Zn-In coating.
• Coatings that are anti-spark.
• Fabrications for the construction industry.
• Restoration of architectural forged iron ornaments.
• Surfaces of bearings and seals
• Anti-corrosion coatings for boilers.
• Reclamation of brake drums
• Reclamation of a Caterpillar V12 Engine Block.
• Playground equipment for kids.
• Cookware with a stainless steel coating that is strengthened.
• Wire barrel for the crane.
• Brake drum clutch housing for forklifts and earthmovers.
• Plastic with a glass reinforcement (GRP).
• Platform for helicopter landings.
• Aluminium tubing with several voids for AC condensers.
• The metal nickel electroforms.
• Coatings that prevent slipping.
• Applications involving nuclear power.
• Oil and gas/offshore
• Foam with an open cell structure.
• Rolls from a paper mill.
• Site for petrochemical processing.