Among all the various material build-up and thermal spray systems that we utilize at MBI, the Twin Wire Arc spray process is considered a favorite. This process is known to be the work horse of our industry. It allows us to apply and build up advanced coating materials fast, inexpensively and at high efficiency rates, which translates into savings to our customers.
Electric Arc Spray Process, aka 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. 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. 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 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.
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.
Also, with our process parts remains relatively cool during the coating build-up (Cold process) avoiding warping, damage and metallurgical changes to the substrate /part material. Our Arc spray processes produce coatings that are versatile in terms of properties and characteristics for favorable hardness, thickness and material composition.
Arc Spray Common Materials
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