Electric Arc Spray Coating
Arc Spray Coating Services
Arc spray coating services for metal, alloy and cored wire coatings used in corrosion protection, surface rebuilding, dimensional restoration and industrial component repair.
APT Coating supports arc spray projects with BP400 and 9935 arc spray systems, handheld spray operation, optional X-Y axis manipulator support and material selection for metal wire, alloy wire and cored wire coatings.
Application Starting Points
Find the Right Arc Spray Coating Route
Start with the surface problem, then match the coating material, process route, finishing method and inspection plan.
For Corrosion Protection
Use arc spray metal coatings for large-area corrosion protection on steel structures, machinery parts and industrial components exposed to harsh environments.
View DetailsFor Surface Rebuilding
Apply metal, alloy or cored wire coatings to rebuild worn surfaces before machining, grinding or final finishing when component geometry allows.
Request SupportFor Repair Coating
Arc spray coating can support repair work on shafts, rollers, housings and mechanical parts where surface restoration is required.
View DetailsFor Wire Material Selection
Select metal wires, alloy wires or cored wires according to corrosion exposure, wear condition, surface function and finishing requirements.
View DetailsProcess Overview
What Is Arc Spray Coating?
Arc spray coating, also known as electric arc spray coating or wire arc spray coating, is a thermal spray process that uses an electric arc to melt two electrically conductive wires and atomizes the molten material onto a prepared surface.
The process is widely used for metal coating, alloy coating, corrosion protection, surface rebuilding and dimensional restoration. It is often selected when large coating areas, practical repair work or cost-efficient metal deposition are required.
Arc spray coating can be applied using metal wires, alloy wires or cored wires. The selected wire material depends on the substrate, working environment, corrosion exposure, wear condition, required coating thickness and final surface function.
APT Arc Spray Equipment & Processing Capacity
BP400 and 9935 arc spray systems for metal, alloy and cored wire coatings, with handheld operation and optional X-Y axis manipulator support.
APT Coating’s arc spray workshop is configured for metal and alloy wire coating applications on industrial components requiring corrosion protection, dimensional restoration, surface rebuilding or functional metal coatings.
The arc spray capability is supported by BP400 and 9935 arc spray systems, allowing APT to process different coating requirements based on part size, coating material, working condition and production method.
Arc spraying can be performed by handheld operation for flexible coating work on complex shapes, repair parts and localized coating areas. For long shafts, rollers, cylinders and repeated coating work, the process can also be supported by a custom X-Y axis spray manipulator, helping improve spray path control and coating consistency.
APT supports arc spray wire materials including metal wires, alloy wires and cored wires. Material selection can be based on the required function, such as corrosion protection, surface rebuilding, wear resistance, electrical conductivity, thermal properties or repair coating requirements.
This process is commonly used for large-area metal coating, anti-corrosion protection, shaft restoration, roller surface rebuilding, machinery repair and industrial component surface enhancement.
- BP400 arc spray system
- 9935 arc spray system
- Handheld arc spray operation for flexible coating work
- Custom X-Y axis manipulator support for shafts and rollers
- Metal, alloy and cored wire coating materials
- Suitable for corrosion protection, repair coating and surface rebuilding
BP400 Arc Spray System
Supports metal and alloy wire coating applications for industrial repair, protection and surface rebuilding work.
9935 Arc Spray System
Used for arc spray coating projects requiring stable wire feeding, controlled spraying and functional metal coating deposition.
Handheld Spray Operation
Allows flexible coating work on complex shapes, localized repair areas and components that require manual spray adjustment.
Custom X-Y Axis Manipulator
Supports controlled spraying for shafts, rollers, cylinders and repeated coating paths where movement consistency is required.
Metal, Alloy & Cored Wires
Supports metal wires, alloy wires and cored wires selected according to corrosion, repair, wear or functional coating requirements.
Repair & Corrosion Protection Applications
Suitable for dimensional restoration, anti-corrosion coating, surface rebuilding and industrial component protection.
Arc spray coating material, thickness and finishing method should be selected according to the base material, component geometry, service environment and required surface performance.
Materials and Selection
Arc Spray Materials and Project Fit
Arc spray material selection depends on the base material, corrosion exposure, wear condition, coating thickness, surface function, finishing route and inspection requirements.
| Material Type | Typical Options | Common Purpose |
|---|---|---|
| Metal Wire Coatings | Zinc, aluminum, steel and selected conductive metal wires | Large-area corrosion protection, surface rebuilding and functional metal coating applications. |
| Alloy Wire Coatings | Stainless steel, nickel alloy and other alloy wire systems | Corrosion resistance, oxidation resistance, dimensional restoration and industrial component repair. |
| Cored Wire Coatings | Wear-resistant, corrosion-resistant or application-specific cored wires | Repair coating, surface rebuilding, wear improvement and project-specific surface functions. |
| Anti-Corrosion Arc Spray Coatings | Zinc, aluminum or alloy-based corrosion protection systems | Protect steel structures, machinery components and industrial parts exposed to corrosive environments. |
For dense carbide coatings and high wear-resistant surfaces, HVOF or D-Gun may be more suitable. For ceramic, oxide or thermal barrier coatings, plasma coating may be the better route.
Applications
Typical Industrial Applications
Large-Area Corrosion Protection
Arc spray metal coatings are suitable for corrosion protection on steel components, machinery frames and large industrial surfaces.
Shafts and Rollers
Metal, alloy or cored wire coatings can be used for shaft restoration, roller rebuilding and surface repair before final finishing.
Machinery Repair Components
Arc spray supports repair coating for housings, worn surfaces, mechanical parts and maintenance projects.
Steel Structures and Industrial Parts
Zinc, aluminum or alloy wire coatings can support anti-corrosion protection for selected steel structures and equipment parts.
Dimensional Restoration
Arc spray can rebuild worn dimensions when coating thickness, adhesion, geometry and finishing requirements are suitable.
Functional Metal Coatings
Selected wire materials can provide electrical, thermal, corrosion-resistant or repair-related surface functions.
Benefits
Why Use Arc Spray Coating?
Arc spray is suitable for metal and alloy coating deposition on repair, rebuilding and protection projects.
Handheld arc spray operation supports localized repair work and complex component shapes.
Custom X-Y axis manipulator support helps improve spray path control for shafts, rollers and repeated coating work.
Metal wires, alloy wires and cored wires can be selected according to corrosion, repair, wear or functional requirements.
Arc spray metal coatings are widely used for anti-corrosion protection on steel and industrial components.
Worn surfaces can be rebuilt when part geometry, coating thickness and post-coating finishing are suitable.
Workflow
How APT Coating Handles Your Arc Spray Project
Application Review
Review drawing, base material, coating area, failure mode, corrosion exposure, wear condition and required surface function.
Wire Material Selection
Select metal wire, alloy wire or cored wire according to coating function, service environment and finishing requirements.
Cleaning and Surface Preparation
Clean the component, protect non-coated areas and prepare the surface before arc spray coating.
Arc Spray Coating
Apply metal, alloy or cored wire coating using handheld operation or X-Y axis manipulator support when suitable.
Finishing or Machining
Coordinate machining, grinding or polishing when the coated surface requires dimensional restoration or surface finish control.
Inspection and Delivery
Review coating appearance, thickness, dimensions and project-specific inspection requirements before delivery.
Process Comparison
Arc Spray Compared with Other Thermal Spray Processes
Arc spray is often selected for metal wire coatings, large-area corrosion protection, surface rebuilding and repair coating. HVOF and D-Gun are usually considered for dense carbide coatings and demanding wear resistance, while plasma coating is often selected for ceramic, oxide and thermal barrier coatings.
Related Capabilities
Explore Related APT Coating Capabilities
APT Coating connects coating services, consumables, auxiliary equipment and technical resources to support complete thermal spray coating projects.
Coating Services
Arc Spray Coating Services
Consumables & Spare Parts
Auxiliary Equipment
FAQ
Arc Spray Coating Services FAQ
What is arc spray coating used for?
Arc spray coating is used for metal coating, corrosion protection, surface rebuilding, dimensional restoration, repair coating and selected functional metal coating applications.
What is electric arc spray coating?
Electric arc spray coating is a thermal spray process that melts two electrically conductive wires with an electric arc and atomizes the molten material onto a prepared surface.
What materials can be used for arc spray coating?
Arc spray coating can use metal wires, alloy wires and cored wires. Common material choices depend on corrosion exposure, wear condition, coating thickness and required surface function.
Can arc spray coating be used for corrosion protection?
Yes. Arc spray metal coatings, including zinc, aluminum and selected alloy systems, are commonly used for anti-corrosion protection on steel and industrial components.
Can arc spray coating repair worn parts?
Yes. Arc spray coating can support dimensional restoration and surface rebuilding when the component geometry, coating thickness, adhesion and finishing requirements are suitable.
How is arc spray different from HVOF coating?
Arc spray uses wire materials and is often selected for metal coating, large-area corrosion protection and surface rebuilding. HVOF uses powder materials and is often selected for dense carbide coatings and demanding wear resistance.
Can arc spray coating be machined after spraying?
Yes. Many arc spray coatings can be machined, ground or finished after spraying depending on the coating material, thickness, surface function and final dimensional requirements.
What information is needed for an arc spray coating quote?
Please provide drawings, part photos, base material, coating area, wire material requirement if known, working environment, failure problem, target thickness, quantity and finishing requirements.
Need an Arc Spray Coating Solution?
Send us your drawing, part photos, base material, coating area, working condition and repair requirement. APT Coating can review whether arc spray coating is suitable for your component.