Electric Wire Spray

The basic form of thermal spray coating is electric wire spray. The process is similar to arc welding where two conductive wires are fed into a spray gun. The wires must be electrically conductive including aluminum, stainless steel, zinc or blended alloys. At an intersection point inside the gun, the wires arc which causes the metal wires to melt. Pressurized air forces the melted wire out of the nozzle of the gun to accelerate the melted particles towards the coating surface. When the particles make contact with the target, they form a series of splats which make up the coating.

Electric wire spray coating has two key advantages over other thermal spray methods. It is the most economical form of thermal spray coating system, and the equipment is maneuverable and can be easily transported throughout a factory or to a job site. Common applications involve the coating of aluminium or zinc to guard against corrosion.

This coating method is also used to spray stainless steel. This is the most common method of spraying babbitting materials and can be commonly found in industrial coating facilities.

Strategic Masking to Ensure Precision Electric Wire Spray Coatings - PTFE Group produces tapes, fabrics, and compounds that are engineered to withstand the forces of Twin Wire Arc coating methods. All have exceptional resistance to high temperatures and abrasion. They are also highly conformable, have excellent adhesion and can be removed cleanly and easily to save time and added expense.

Key Considerations:

  • While Plasma Spray Masking Tape may be sufficient in most smaller scale masking situations, you can avoid excessive tape use on larger objects by using a re-usable masking blanket. Determine the best type of masking - The masking blanket is best used in conjunction with Plasma Spray Masking Tape.

Recommended Materials

For strategic masking prior to arc-spray coating process, we recommend the following materials: