Electric Arc Processes

Electric Arc Processes

Electric Arc is ideal for metallic, heavy coatings but can present ergonomic challenges for operators.

Thermach systems are specially designed to help lower operator fatigue and significantly reduce maintenance costs. Our AT-400 system uses the “push” method, the driving force is a bigger, more robust wire drive motor located within the control console instead of the torch. Our lightweight AT-400 torch with quick change wire guides delivers ergonomic benefits unavailable with any other system.

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How Electric Arc Spray Works

How Electric Arc Spray Works

Electric Arc, commonly referred to as twin wire arc spray, is one of the most productive and economical thermal spray processes. The coating material, in wire form, is fed via a wire feeder into a torch head and electrically charged, one positive and the other negative. The wires are then forced together and create an electric arc, melting the wire. The molten material is then atomized and propelled towards the prepared substrate as compressed air passes out the air cap. The tiny molten droplets then hit the desired substrate and flatten out and make splats. These splats interlock with each other to create extremely strong mechanical bonds.

Electric Arc Torch Nomenclature

  1. Wire
  2. Compressed Air
  3. Negative Voltage
  4. Positive Voltage
  5. Wire guides
  6. Air Cap

Where Electric Arc Excels

Aluminum Bronze sprayed with AT-400 Torch

Where Electric Arc Excels

Simple to use, with highly reliable surface results, Electric Arc Spraying creates some of the fastest coating rates of any coating method. Whether your project calls for a smooth, rough, thin, or thick coating, Electric Arc Spray can provide the results you are looking for. Some of the benefits of utilizing Electric Arc Spray are:

  • Cost Savings
  • High Mechanical Bonds
  • Faster and More Productive
  • Applied at Lower Temperatures
  • High Deposition Rates
  • No Combustible Gases
  • Easy to Operate and Automate
  • Can Spray Pure Metals or Alloys
  • No Cure Times
  • Can Achieve Different Coating Textures
  • Can Be Hand Sprayed
  • Easy to Change Over Between Materials
  • Not Subject to Degradation

Electric Arc Applications

Electric Arc Applications

Thermach thermal spray equipment is a smart, reliable choice for coatings, in the factory and in the field. Here are the applications where Electric Arc Spray is typically used.

  • Dimensional Restoration
  • Bearing Fit Rebuilding
  • Abrasion Resistance - Air Movement Components
  • Shaft Repair
  • Sacrificial Coatings
  • High-Temperature Resistance
  • Gripping and Anti-Skid Surfaces
  • Boiler Repair
  • Corrosion Resistance
  • Abradable Coatings
  • Biofouling Prevention
  • Electrical Connectivity
  • Traction Rolls
  • Bond Coats
  • EMI/RFI Shielding