Arc wire spraying

Electric wire spraying is a technique in which two electrically conductive wires are transported through a spray gun. An electric arc is produced between the ends of the two wires causing them to melt. Compressed air is used to transport the molten material to the substrate where it forms a coating.

Arc wire spraying2

This process allows coatings to be applied quickly and at low energy costs. The major benefits of electric wire spraying are its large spraying capacity and excellent adhesion. The equipment can be operated at a low energy costs and it is very mobile making the process suitable for working on location.

Process properties

Material Form: Electrically conductive wires or cored wires
Thermal energy source: through electrical gas discharge (arc)
Process temperature: 4,000 ºC
Spray particle speed: < 200 m/s


  • Micro porous lamellar structure
  • High degree of oxidation in the coating
  • Excellent adhesion and density of the coating
  • Simple process
  • Versatile and reliable
  • High production capacity
  • Economic thermal spraying process
  • Transportable process, spraying on location possible

Typical coatings

  • Various stainless steel alloys
  • Nickel-based alloys
  • Copper and copper alloys
  • Aluminium
  • Zinc


  • Boiler walls of incinerators against high-temperature erosion and chemical degradation
  • Repairs and dimension corrections of worn drive shafts and bearing seatings with nickel-based alloys
  • Corrosion protection for locks, bridges, etc. with aluminium, zinc and alloys
  • Electrical shielding with tin, zinc, etc.
  • Anti skid and traction coatings


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