Electric Arc Wire Spray

Electric Arc Wire Spray

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



Arc temperature

Approx. 4,000 °C

Particle velocity

Approx. 150 m/s

Spray performance

15 – 3,300 g/min

Schematic diagram of an electric arc wire process.

Key characteristics

  • Excellent portability for on-site coatings
  • Does not require any process water or gasses except compressed air
  • High spray rates

Typical applications

  • Bridge decks
  • Transport pipes
  • Capacitors
  • Welded tube seams
  • Piston rings
  • Varistors
  • Boiler walls
  • Other large infrastructures
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