How twin-wire arc spraying works
An electric arc melts the tips of two conductive wires fed into the spray gun. Compressed air atomizes the molten metal and propels it onto the part.
Twin-wire arc is often more cost-effective than higher-energy processes like plasma or HVOF. It suits large surfaces and cost-sensitive projects in industries such as infrastructure, marine and manufacturing.
Our computer-controlled system precisely regulates spray head air pressure and automates the spray rate. That produces high-density coatings with excellent bond strength, repeatable from part to part.
Materials
| Material | Used for |
|---|---|
| Zinc | Sacrificial corrosion protection for bridges, pipelines and marine structures |
| Aluminum | Lightweight corrosion protection for ship hulls and chemical plants |
| Zinc-aluminum | Corrosion resistance and durability for structural steel and wind turbines |
| Stainless steel | Wear and corrosion resistance for machinery and pump shafts |
| Nickel-chromium | High-temperature resistance for boiler tubes and turbines |
| Copper | Electrical conductivity for bus bars and connectors |
| Bronze | Reduced friction in bearings and marine hardware |
Applications
- Corrosion protection: zinc or aluminum coatings shield bridges, pipelines, offshore platforms and ship hulls from rust and saltwater.
- Dimensional restoration: low-carbon or stainless steel coatings rebuild worn parts like crankshafts and hydraulic cylinders.
- Bond layers: a metal bond coat under ceramic and other top coats.
- Electrical conductivity: copper coatings for connectors and bus bars.
- High-temperature resistance: nickel-chromium coatings protect boiler tubes and turbines from heat and oxidation.
Combustion flame spray
Flame spraying melts the coating material in an oxy-fuel flame. We use it alongside twin-wire arc for dimensional repair, and it is the first step of our spray-and-fuse coatings. Abradable coatings are also typically applied by plasma or combustion flame spray.
