What is Arc spray?

Arc spray uses metal wires as the coating material. An electric arc provides the heat source, one positive and one negative wire.  The opposite charged wires short circuit, forming a plasma temperature of 4,000°C.   The wire melts, and once molten, compressed air to atomize and accelerate the feed metal towards the substrate.

Arc spray can also spray two different wires simultaneously to produce a pseudo alloy, often a bronze and a steel wire are used for coating cylinder heads and engine block.  Cored wires containing tungsten carbides and special alloys can be sprayed as well.

Arc spray systems for aluminium and zinc have extremely high spray rates and can coat large areas quickly.

Arc spray process diagram

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What is HVOF spray?
HVOF is a High Velocity Oxygen Fuel.  The HVOF is a combustion process.  HVOF fuels can be Hydrogen, Propane, Natural Gas, or a liquid fuel such as kerosene.

The combustion process generates an extremely high velocity gas stream. The gas stream propels the powder particles at near supersonic speeds. 

HVOF key benefits are the extremely dense and low oxide coatings. Low oxides:  Since the powder particles spend less time in the flame, and lower flame temperature 3,000 °C compared with plasma spray:  HVAF (high velocity air fuel) has an even lower flame temperature than HVOF, and produces coatings that are even less oxidized, and more ductile.

As well as producing excellent bond strength, some HVOF coatings can be sprayed very thick due to the exceptionally high velocities producing coatings in compression instead of tension.

Learn more about the latest process of HVAF, high velocity air fuel, and HVAF C combining both high velocity air fuel, and high velocity oxygen fuel process in one system.  Click here to learn more about high velocity oxygen fuel

Typical HVOF coatings

  • Tungsten carbide
  • Chrome Carbide
  • Nickel & Cobalt based super-alloys, Stellite,
  • Triballoy, Inconel,
  • Iron based alloys, AISI 316L, etc.
  • MCrAlY

Main Industries applications

  • Aerospace and Industrial Gas Turbine
  • Paper Industry
  • Oil, Gas, Mining
  • Replacement of Hard Chrome
  • Wear resistance Sliding, Abrasive, Erosion, etc.
  • Chemical resistance
  • High Temperature applications


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What is thermal spray ?

What is thermal spray: "Thermal spray technology is a process of applying a coating to a surface using a high-velocity stream of molten or semi-molten particles. This process is often used to improve the surface properties of a material, such as increasing its wear resistance or corrosion resistance.

The thermal spray process involves heating a wire or powder material to a semi-molten or molten state, and then accelerating the material through a nozzle using a high-pressure gas. The material is then sprayed onto the surface to be coated, where it rapidly cools and solidifies.
One of the key advantages of thermal spray is that it can be used to apply a wide range of materials, including ceramics, polymers, and metals. This makes it a versatile option for a variety of coating applications.

Thermal spray has a wide range of applications, including aerospace, automotive, and biomedical industries. It is also frequently used in the repair and maintenance of equipment and machinery.

Stay nerdy and keep up with the latest developments in thermal spray technology!"

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