The main advantages of arc spraying relate to its ease of use and high coating rates:
- Arc spraying has the highest deposition rate of the thermal spraying processes, with rates of 15kg/hr or higher.
- The process can offer lower cost coatings when compared with plasma and HVOF spraying. This is because of lower energy cost, high deposition rates and efficiencies and lower material costs associated with a wire consumable.
- Power input is very low at only 5-10 kW compared with greater than 50kW for plasma and HVOF spraying systems.
- Little operator training needed.
- Low heating of the substrate makes arc spraying useful in metallizing thermally sensitive substrates such as capacitors and similar electronic components.
- It is possible to spray two dissimilar wires and produce an intimately mixed coating. Examples include composites of copper and steel on brake discs and clutch pads, and composites of steel and bronze on bearing surfaces and machine tool slideways.
- Higher bond strengths than achievable with flame spraying, even for thicker coatings. Bond strengths are similar over a wide range of spray angles.
- Lower porosity levels than can be achieved by powder flame spraying.
- Arc spraying does not require use of combustion gases or produce a high-energy plasma, and consequently poses fewer Health & Safety risks than other thermal spray processes.
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