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Twin Wire – Arc Spray

High-Strength Metal Coatings at a Low-Cost

Twin Wire – Arc Spray

Twin wire arc spraying is the best choice for all-purpose spraying, as coatings can be applied fast and at a low cost. A wide variety of metal coating materials are available, from aluminium through to tungsten carbide, offering high bond strengths, high deposition rate and minimal substrate heating. Sprayed metal is usually harder in wrought form with higher lubrication properties.

Manufactures in multiple industries, including electrical, automotive, marine, power generation, and electronics have taken advantage of the benefits of using electrical-arc spray in their operations.

Twin wire arc spray uses two metallic wires 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 the wires are brought together at the gun, the opposing charges on the wires create enough heat to continuously melt the ends of the wires.

Compressed air is used to atomize the now molten material and accelerate it onto the work piece surface to form the coating. Bond strengths of around 9,000 psi (pounds per square inch) are achievable. In wire arc spray, the weight of coating that can be deposited per unit of time is a function of the electrical power (amperage) of the system and the density and melting point of the wire.



Manufactures coating both metal and non-metal substrates can utilise twin wire arc spray to:

  • Increase the longevity of parts by making them more resistant to wear, abrasion, or corrosion.
  • Restore worn parts to their preferred dimensions for a lower cost than replacing the part.

Typical Application:

  • Atmospheric and Heat Corrosion Control
  • Rebuild and Salvage Operations
  • Bond Coats
  • Electrically Conductive and Solderable Coatings
  • Anti-skid and Traction Coatings

Twin wire arc spray can be easily applied using a hand-held unit, or incorporated into a fully automated production system. Recent advancements in equipment design and technology have introduced electric-arc spray into new fields of application, such as mould-making, anti-skid coatings and decorative coatings, due to its adaptability to various applications.

Twin wire arc spray is commonly used for reclamation of worn, damaged or mismachined parts, such as the repair of bearing and seal journals on shafts and differential housing bores. It can be applied to rebuild components to new sizes beyond OEM (Original Equipment Manufacturer) tolerances in consultation with subject matter experts.

Exciting new applications for twin wire arc spray are constantly being discovered. It can also be used to coat architectural elements for buildings or artistic sculptures prior to installation. Anti-skid coatings can be applied to offshore oilrig walkways as well as aircraft and ship stairways to make them safer.

Of all the thermal spray processes, twin wire arc spray has the highest deposition rate, great bond strength, and fastest application time and is a more cost effective method for reclaiming components. Contact us to find out how we can assist you with all of your twin wire application needs.