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Wire Spraying

Last updated: August 5, 2020

What Does Wire Spraying Mean?

Wire spraying is one of the processes of thermal spraying where two consumable metal wires are fed independently into the spray gun. These wires are then charged and an arc is generated between them. The heat from this arc melts the incoming wire, which is then sprayed via air jet from the gun. This entrained molten feedstock is then deposited onto a substrate.


Corrosionpedia Explains Wire Spraying

The thermal wire spray coating processes involves the deposition of coatings from a stream of high-velocity finely divided particles in a molten or semi-molten state impinging onto the substrate. These processes use metal wire that is molten and broken into fine droplets. The coating gun adds thermal energy to bring the materials to a plastic or molten condition and accelerates these materials at high velocities toward the substrate.

diagram of wire spraying process

Key characteristics:

  • Heat source: Fuel and oxygen
  • Material: Wire (metal)
  • Flame temperature: Approx. 3,100°C
  • Particle velocity: Up to 200 m/s
  • Spray performance: 15 - 1,400 g/min
  • Portable for on-site coatings
  • High spray rates with low gas consumption

Resulting Properties:

  • High thickness buildup and high coating rates possible
  • Strong adhesion
  • Uniform coating and good density
  • Process of choice for high-volume coating of metal alloys

Typical wire coating materials:

Three basic types of deposits can be thermal sprayed:

• Single-phase materials, such as metals (Al, Zn), alloys (Zn-Al, Al-Mg), intermetallics, ceramics, and polymers

• Composite materials, such as cermets (WC/Co, Cr3C2/NiCr, NiCrAlY/Al2O3, etc.), reinforced metals, and reinforced polymers

• Layered or graded materials, referred to as functionally gradient materials (FGMs)


  • Steel structures
  • Transport pipes
  • Storage tanks
  • Process basics

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