Arc Spray Coating Process

Twin Wire Arc Spray Process

The electric arc spray coating process is a welding process that uses an electric arc as the heat source to melt metal wires. The melted metal is shot through compressed air to create a stream that is used to directly apply a coating product onto a surface. Our Arc Spray process keeps the wire both strong and pliable, without making the material brittle. Arc Spray coating is best used for surfaces that need traction and grip and/or nonstick. By using Arc spray, we can engineer surfaces quickly and economically.

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How it Works

Also known as the Twin Wire Arc Spray process, two wires of desired materials act as electrodes when they’re fed through a spray gun. The gun is connected to a high-current (DC) power source to facilitate an arc between them. Then, an air stream thru the back of the gun atomizes and propels the molten particles towards a prepared surface. With adjustable parameters including voltage and amperage arc temperatures can reach 5000°C, enough to melt any material, at the same time the part surface remains cool. Therefore, the process is considered energy efficient because all of the input energy is used to melt the spray materials.

Spray rates are driven primarily by the operating current and, consequently, vary as a function of both melting point and conductivity. Generally, materials such as iron-base alloys including stainless steel materials spray at 4.5 kg (10 lb)/100 A/h. Aluminum and Zinc spray at 11 kg (25 lb)/100 A/h.

The MBI Difference

At MBI we employ high-velocity twin wire arc spraying to produce coatings that have extremely high bond strength (over 13,000 psi), lower stress, and higher densities than what others can produce.

With our cold process, parts remain relatively cool during the coating build-up to avoid warping, damage, and metallurgical changes to the substrate or part material.

As a result, our Arc spray processes produce coatings that are versatile in terms of properties and characteristics for favorable hardness, thickness, and material composition.

Common Applications

  • Feed Rolls & Non-slip Surfaces

  • Corrosion Protection Work

  • General Journal Build-up & Repair

  • Specific Alloy Build-up Material

  • Replace Galvanizing

  • Heavy Build-up Requirements

  • Chrome Plating Replacement Coatings

Key Advantages

  • Very High Bond Strength

  • Versatile Hardness to Machine or Grind

  • Versatile Build-up: .003” to >.0.300”

  • Versatile Finishes: Smooth to Extra-Rough

  • High Ductility with Low Stresses

  • High Density with Low Porosities

Let’s Work Together

Whether you need to enhance the performance of your equipment or repair worn-down surfaces, MBI Coatings can help. Put our advanced surface engineering to work in your business.

Contact us today to learn more.

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