ARC SPRAY GUN AND
TWIN WIRE ARC SYSTEMS.
Metaflux Spray Solutions manufactures twin wire arc spray guns and arc spray systems in Pimpri-Chinchwad, Pune, India, for applying zinc, Zn-Al and aluminium anti-corrosion coatings to bridges, penstocks, ducting and structural steelwork.
Cold Process
< 150°C SubstrateHigh Volume
15 – 30 kg/hr ZincAnti-Corrosion
Zinc / AluminiumTwin Wire Arc Spray System
A DC arc struck between two continuously fed wires melts the metal; compressed air atomises it onto the workpiece. There is no oxy-fuel flame, so no fuel gas cylinders are needed on site — which is why arc spray is the usual choice for large fabrication yards and bridge contracts.
TYPICAL
SPECIFICATIONS.
Typical operating data for twin wire arc spray guns and their power supply and control units. Exact specifications vary by configuration — request a datasheet for the model you are evaluating.
| Parameter | Typical Range |
|---|---|
| Process | Twin wire electric arc spray (TWAS) |
| Wire Diameter | 1.6 / 2.0 / 2.5 mm |
| Wire Materials | Zinc, Aluminium, Zn-Al 85/15, Carbon Steel, Stainless Steel, Bronze, Cored Wires |
| Output Current | 100 – 500 A DC |
| Arc Voltage | 18 – 40 V DC |
| Duty Cycle | 100% at rated output |
| Deposition Rate — Zinc | 15 – 30 kg/hr |
| Deposition Rate — Zn-Al 85/15 | 12 – 25 kg/hr |
| Deposition Rate — Steel / Stainless | 10 – 18 kg/hr |
| Deposition Rate — Aluminium | 5 – 10 kg/hr |
| Atomising Air | 60 – 110 m³/hr (35 – 65 CFM) at 5 – 6 bar |
| Spray Distance | 100 – 200 mm |
| Substrate Temperature | Typically below 150 °C |
| Gun Weight | 2.5 – 5.0 kg (push-pull head) |
| Cable / Hose Length | 3 m, 5 m or 10 m |
FREQUENTLY ASKED
QUESTIONS.
The questions coating contractors and fabrication yards ask most often about twin wire arc spray equipment.
What is the deposition rate of an arc spray gun?
A twin wire arc spray gun typically deposits 15 to 30 kg/hr of zinc, 12 to 25 kg/hr of Zn-Al 85/15, 10 to 18 kg/hr of carbon or stainless steel and 5 to 10 kg/hr of aluminium. The actual rate follows the wire diameter and the current setting, which runs from 100 to 500 A DC on Metaflux arc spray systems. Higher current means more melted wire per minute, not a better coating, so the rate is set to suit the job.
What is the difference between arc spray and wire flame spray?
Twin wire arc spray melts two consumable wires with an electric arc and atomises the melt with compressed air, while wire flame spray melts a single wire in an oxy-fuel flame. Arc spray deposits roughly two to three times faster on zinc and needs no fuel gas on site; wire flame spray uses a lighter gun and only needs cylinders and an air supply. Metaflux Spray Solutions manufactures both processes in Pune.
Does twin wire arc spray need fuel gas on site?
No. Twin wire arc spray melts the wire electrically, so no oxygen or fuel gas cylinders are needed — only an electrical supply for the power source and clean, oil-free compressed air at 5 to 6 bar for atomising. That is why arc spray is the usual choice for large fabrication yards, shipyards and bridge sites where storing combustible gas is restricted.
Which wire materials can a twin wire arc spray system apply?
A Metaflux twin wire arc spray system applies zinc, aluminium, Zn-Al 85/15, carbon steel, stainless steel, bronze and cored wires in 1.6, 2.0 and 2.5 mm diameters. Zinc and Zn-Al are used for long-life anti-corrosion coatings on structural steel, ducting and penstocks; steel and cored wires are used to rebuild worn or undersized components.
Will arc spray distort thin steel sections?
Arc spray typically holds the substrate below 150 °C, so thin steel sections do not distort and the base metal structure is unchanged. The coating bonds mechanically to a grit-blasted surface rather than metallurgically, which is why surface preparation controls adhesion far more than spray parameters do.
How much does an arc spray machine cost in India?
Metaflux Spray Solutions quotes arc spray system prices on request, because the price depends on the rated current, the push-pull gun and cable length chosen, and the wire and spares package included. Send the coating material, the component size and the required output through the enquiry form on this page for a written quotation from Pune.
Twin Wire Arc Spray Applications
and Coating Materials.
Zinc / Alu
Bridges, ducting, penstocks and structural steelwork.
Fast Feed
Up to 30 kg/hr on zinc, depending on wire diameter and current.
Dense Bond
Strong mechanical adhesion on grit-blasted cast and fabricated steel.