Electric Arc Spray Coatings: Advanced Twin Wire Thermal Spraying

Electric Arc Spray Coatings, also known as twin wire arc spray coatings, are a specialized form of thermal spraying that involves feeding two consumable wires into a spray gun. As these wires are charged, an electric arc forms between them, generating intense heat that melts the feedstock wire. The molten droplets are then propelled by an air jet through the gun’s nozzle, where they impact the component’s surface and form a durable coating.

Arc spray coatings produce wide plumes, making precise masking a critical aspect of the process.

Electric arc spray coatings are widely used in industries such as Aviation/Aerospace, Energy (Industrial Gas Turbines), Semiconductors (Parts Cleaning), and Marine (corrosion resistance). These coatings are particularly effective for applications requiring corrosion resistance (using sprayed aluminum or zinc), conductive coatings, and wear-resistant coatings.

Click here to download our Electric Arc Spray Coatings brochure.

Recommended Products for Electric Arc Spray

– 6605-07D: A basic single-sided glass cloth tape, ideal for non-critical abrasive blasting masking. It’s a reliable option for single-layer secondary masking.

– 6615-07: A double-sided fiberglass tape, 7 mil thick, featuring silicone adhesive on both sides and a crepe paper liner. This tape offers excellent conformability and strong adhesion to metal, making it perfect for face-to-back masking.

– 6615-12: A thicker, 12 mil double-sided fiberglass tape, ideal for single-layer plasma spray masking.

– 6625-11: An aluminum foil flame spray masking tape, 11 mil thick with a 4 mil foil layer, providing robust protection.

– 6525-08: An all-purpose abrasive blasting masking tape, suitable for both grit blasting and air plasma applications. This tape is constructed with silicone rubber-coated fiberglass and features a silicone adhesive.

– 6525-16: A double-layered masking tape that allows for single-layer application, reducing masking time by 50% in situations where two layers of standard tape would be required.

– 7422W: A heavy silicone-coated fiberglass fabric designed for demanding jobs that require protection of large surfaces. This fabric is more abrasive-resistant and is well-suited for both primary and secondary masking tasks.

Masking Compounds

– TacMold (A2023-A / A2023-B): A two-part silicone putty designed to withstand all forms of thermal spray, including GF-HVOF and LF-HVOF. TacMold is ideal for masking holes or intricate profiles and is reusable in some cases.

– TacBloc: A soft, conformable, putty-like material designed for masking holes, grooves, key slots, or other unique configurations. Unlike TacMold, TacBloc adheres directly to metal, making it ideal for areas where anchorage is difficult. TacBloc is suitable for all types of thermal spray.

For detailed guidance on maximizing the benefits of our TacMold & TacBloc Masking Compounds, please log in or register to download our comprehensive How-to Guide.