Twin Wire Arc Spray

Industrial Metal Coating Services in Perth

Reclaim worn, damaged or mis-machined components.

As expert providers of corrosion control engineering, New Metal Surfaces offers an extensive range of industrial metal coating services.

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 to tungsten carbide, offering high bond strengths, high deposition rates and minimal substrate heating. Sprayed metal is usually harder in wrought form with higher lubrication properties.

Manufacturers in multiple industries, including electrical, automotive, marine, power generation, and electronics have taken advantage of the benefits of using electrically conductive coatings in their operations. Twin wire electric arc spraying makes use of two metallic wires as the coating feedstock. These 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 atomise the now molten material and accelerate it onto the work piece surface to form the ‘wire 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.

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 mis-machined 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 as it can also be used to coat architectural elements for buildings or artistic sculptures prior to installation. Anti-skid coatings can also 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, as well as being a more cost effective method for reclaiming components.

Contact us now to find out how we can assist you with all of your twin wire application needs.