Arc Spray

arc spray

What is arc spray?

Arc spray uses electricity and the heat of a current arc to melt wire material. Arc thermal spray systems continuously feed two wires into a gun assembly where the wire is heated. These two wires can be the same material or two different materials. This includes the use of cored wire to form special alloys for better wear or corrosion characteristics. Compressed air propels the coating onto the desired surface creating a durable metal coating. Due to the high heat and spray velocity, arc coatings can be laid down quickly and economically.

arc spray gun diagram

Arc Spray Solutions

Not only can arc spray be applied efficiently; it also achieves good bond strength and hardness during application. This makes it great for building up surfaces that are worn 1/4" or more. This system can also feed two different wire materials into the spray gun and create specialized alloys to tailor the coating for the best surface enhancement solution. Arc spray coatings are wear resistant and can enhance the electrical properties of machine components.

Common Coating Materials & Solutions

  • Monel
  • Inconel
  • Stainless Steel
  • Hastelloy
  • Zinc
  • Aluminum
  • Tin
  • Copper

Arc Spray is great for...

  • Shaft enhancement or repair
  • Enhancing electrical conductivity
  • Feed roll enhancement or repair
  • No slip coating solutions

Arc Spray Coating Properties

 Operating Cost


Bond Mechanism

Mechanical (1,500-9,000 psi)

Max Flame Temperature

Up to 7,000° F

Particle Velocity

160-300 ft/sec

Max Spray Rate

10+ lbs/hr/100 amps

Coating Thickness Range

0.005" to 0.250"

Special Features

Economical, no heat distortion

Wear Resistance


Corrosion Resistance




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