Why Arc Spray is a Great Thermal Spray Solution for Most Coatings
What is arc spraying?
Arc spray, also known as twin wire arc spray, or metal spray, is the all-rounder of industrial coating applications. A popular choice for its strength in coating many different types of materials, at New Metal Surfaces we commonly use arc spray to repair worn or damaged machine parts, correct mis-machined components and improve corrosion control and electrical conductivity.
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Arc Spray Application
Arc spray is a thermal spray process that uses an electric arc to melt wires to create a dense and durable coating. Arc spray coatings are applied using robotic equipment at New Metal Surfaces following the steps below:
Step 1: Surface Preparation
The substrate (or surface) must be cleaned and prepared before applying the coating. This may involve grit blasting and using chemical solutions to remove any contaminants and create a rough surface for the coating to adhere to.
Step 2: Wire Feeding and Arc Generation
Two wires, typically made of metal or alloy, are fed into the arc spray gun. An electric arc is generated between them, causing them to melt.
Step 3: Atomisation and Propulsion
The molten material is atomised into small particles using compressed air and propelled towards the substrate at high speed. The particles hit the substrate and flatten out, creating a coating.
Step 4: Coating Build-up
The process is repeated to build up the thickness of the coating. The coating can be applied in multiple layers to achieve the desired properties and thickness.
Why is Arc Spray a Great Thermal Spray Option?
Versatile
Arc spray is a versatile coating solution that can be applied to a wide range of substrates.
Arc spray can also use a wide range of materials for various applications. The choice of material will depend on the properties required for the coating, such as hardness, chemical resistance, and thermal conductivity.
Adhesion and Bond Strength
Arc spray produces coatings with excellent particle adhesion and bond strength. Whilst it doesn’t reach the same level of bond strength as a process like HVOF (click the link to learn more about HVOF coatings) it is still a process that has high tensile strength, low porosity, and great corrosion resistance.
High Deposition Rates and Thicknesses
Arc spray is a coating process that allows for high deposition rates of material. It can be used to apply large amounts of material to coatings quickly and achieve greater thicknesses than some other thermal spray processes.
Fast and Efficient
Arc spray is a fast and efficient coating process, especially when automated. It can be used to apply coatings quickly and evenly to large surfaces, reducing the amount of downtime and increasing productivity.
Arc spray offers a cost-effective, high-quality coating solution for machine parts and industrial components. The high deposition rates, the thickness that can be achieved and the ability to enhance qualities, like corrosion resistance and electrical conductivity, are what make arc spray such a popular coating choice.
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Contact us to learn more about our HVOF thermal spray coating process or to see if we can help with your coating needs.
