Electric Arc Spraying

Due fili (electrodes, cathodes and anodes) are pushed to the end of a gun, body where an electric arc which merges them into droplets which are then accelerated by the compressed air or gas and fired on the support.

Solid wires normally used

Applications Zinc and its alloys

Al/Mg Coatings resistant to corrosion in marine atmosphere
In Coatings with excellent adhesion
Steels 13% Cr Wear-resistant coatings, insufficient resistance to corrosion
Fe Cr Al Excellent corrosion resistance at high temperatures
Mo Coatings excellent fretting fatigue
Ni Cr 80 20 Corrosion-resistant coatings and binder for ceramic tiles surface

The zinc coatings are excellent for the protection of steel from corrosion because zinc is resistant to basic solutions and atmospheres with low acidity (pH 5-12). There are many industrial applications such as: tubi di ghisa, iron bridges, torri eoliche, capacitors on which creates an electrical contact between the laminae of the metallized film.

Aluminum and its alloys

Al is resistant to acidic and basic atmospheres (pH 2-10), for which it is used in the protection of the food industry, for marine structures and in the pipes and vaporizers of liquid gas tanks. The oxygen content (2,5-3%) electric arc causes a higher resistance to corrosion than spraying gas, whose oxygen content is 0,4%.

The bequeaths AlMg 5% It has excellent corrosion resistance of offshore structures and those in the marine atmosphere. Membership is 20-30 MPa, greater pure aluminum.

Each aluminum-based coating must be sealed to prevent the migration of corrosive vehicles through the pores of the surface.


Bronzes to aluminum

The addition of small percentages of Al alloys of copper increases the resistance to corrosion due to the oxides of Al formed during the spraying and coating. The addition of Ni and Fe to the bronze / aluminum increases the corrosion resistance. In salt water they are more resistant brass and bronze.

Nickel and its alloys

They are used as corrosion of components in desalination and marine atmosphere. The Ni CU30 Fe coatings show excellent corrosion resistance in oxidizing or reducing fluids.

They are comparable to the enamelled steel and are recommended to repair damaged coatings Ni Fe CU30.

The coatings Ni Cr80-20, employing argon as gas atomization, are excellent against corrosion by moisture. Test solutions Na Cl 5% and oxidizing fluids (1N H2 SO4) confirm the excellent corrosion resistance, comparable to that of steel plated.

Anti-friction coatings

Are based on tin and bronze (p.e. with Al18 – with SN6) show a low rate of friction and excellent rub resistance. These coatings can be machined on a lathe. Those at the pond should be applied when the rotating shaft is not hardened, while the toughest coatings based on Cu can withstand higher pressures (a greater number of turns and higher static loads). Their range of application is 200/300 ° C.

high-adhesion coatings

Ni Ni alloys Ti and Al have a high degree of adherence (for ceramic coatings and other materials with a thickness of a few millimeters, etc..)

Due to the exothermic reaction of Al with Ti and oxygen atomizing air, the fused particles are overheated and when impacting on the substrate forming microscopic welding points.

The coatings Ni Al 95-5 arched show a higher adhesion compared to plasma, no major differences in hardness.

wear-resistant coating

They are usually employed different steels such as those hard martensitic (Cr13%,Co0,3-0,47%)(p.e. coatings of carbon steel on the levers of Al).

Due to the combustion of carbon and chromium in the electric arc, the finish of this steel is less harsh in the same heat-treated alloy. It is advisable in this case to use wireless animating containing Co and Cr to integration.

anti-wear coatings in corrosive atmosphere

In many industrial applications, where the materials are subject to wear and corrosion, a coating with standard materials (p.e. steel wire 13% Cr) fails to ensure a long life. It is therefore necessary to use flux cored wires (as tungsten carbides). Coatings with hardness 500-600 HV0,3 obtained from cored wires Fe Cr B is (Cr 28%) instead of Cr 13%, applied on the rollers of the paper have not submitted to the test of incision visible traces of corrosion, while the mild steel support was highly corroded.

Coating reconstruction

Mild steels and high-alloy steels are used to reconstruct trees motor-generators or cylinders for the paper or for re-housing and sealing rotating shafts worn. The bronzes and alloys based on tin can be sprayed liners to repair marine engines.

Corrosion preventive coatings from high temperature

Against the corrosion and / or erosion of the simultaneous and vaporizers and to transport high-temperature vapor tubes, in coal-fired boilers and waste incinerators must apply coatings with cored wire NiCr and FeCr with high chromium content. E 'need to know to choose the suitable parameters (nozzles for spraying and distances, pressure atomization, voltage), in order to reduce the burning of chromium and its oxidation.

Effect of Chromium Metal

The Cr metallic form an oxide film on the surface of the coating, even in the presence of gas at low oxygen content.

A thick coating of chromium oxide determines a longer life of the coated piece in many corrosive atmospheres.

Numerous studies show a corrosion resistance of base coatings of Cr203 better than Fe Ni Cr in an atmosphere with high presence of HCl and SO2 .

Effect of Boron and Silicon

Many coatings are made with NiFe-cored wires with the addition of Si or boron . Typically these two elements lowering the melting point of iron alloys and Ni. The low melting point results in a lower viscosity of the atomized particles to which they may expand more easily to impact with the surface of the substrate giving rise to dense deposits. The porosità (Browsing, ranging from the exterior at the interface between coating and substrate-chin) decreases with the thickness of the coating. However, the latter, if it is too often, may crack due to residual stress that is greater when the thickness is more important.

Cartoons Wires

A longer component life (come caldaie o rulli) You are obtained by replacing solid wires with those animated with charcoal, chromium and aluminum.

Coatings with cored wires with tungsten carbide and nickel showed an excellent resistance to wear by abrasion. At a temperature of 982 ° C the Ni Cr Al cored wires can be sprayed electric arc of worn parts or ceramic deposits.

Type flux cored wire – application

Fe C Mn Si high resistance to wear in a dry atmosphere
Fe Cr B Si coating resistant to wear and tear, good resistance to corrosion, high adherence
Fe Cr B Si W C Co Cr excellent resistance to high temperature corrosion, high adherence
Fe Cr Si resistance to wear and to corrosion at high temperature up to 900 ° C, high adherence
Ni Cr 50 50 corrosion resistance high temperature up to 900 ° C
Ni B Si + WC high resistance to wear, good corrosion resistance
Ni Cr B Si high resistance to corrosion in humid atmosphere,good resistance to wear

The table shows the resistance of various coatings with flux cored wires to the wires than standard steel 13% Cr. The loss of the coating material FE28 Cr3 B1 It is about half of the coating 40 Cr 13.L'ulteriore strengthening of the flux cored wires Cr B Si with WC-Co Cr powder increases the wear resistance. Only the system HVOF WC-Co has a higher resistance.


Type HB durezza day (mm) Steel wire (analisi) %
20L 190-200 1,6 basso C 0,08C-0,45Mn
30L 210-230 1,6 basso C 0,10C-1-1 80mn, 0if
55L 300-320 1,6 1,3% C 1,50C-1, 40Cr-0,6Mn-1, 0if
60L 300-340 1,6-2 Inox 0,45C-13Cr-1 0mn-1 0if-1 0Ni
62L 240-266 1,6 Inox 0,35C-17Cr-0,60Mn-0,50Si-1, 0Ni-1 1Mo
65L 380-440 1,6 High C 1,15C-1, 80Cr,2,0Mn-0,30If-0,20You
80L 220 1,6-2 Inox 18/8 0,40C-19Cr-1 80mn-1, 30Si-9 0Ni
85L 250-270 1,6 Inox 18/8 0,15C-18, 50Cr,7,0Mn-0,9Si-8 50Ni
95L 280 1,6 18/11/2 0,06C-17, 50Cr,2,0Mn-1, 0 if-12Ni,2,5Mo
Type HB durezza day (mm) Wires other metals (analisi) %
70L 160-200 1,6 Monel 0,64Ni-32Cu-2, 50Mn-1, 5Fe
CuL 1,6 Pure Rame 99,99%C
100L 480 1,6 Pure Molybdenum 99,99 %Mo
98L 1,6 Nichel-Chrome 80Ni-20Cr
RniL 160 1,6 Pure Nichel 99,2% Or
NiAl / L 230 1,6 Nichel-Al 93,5Ni-5, 0Al-1, 5Si
PBz / L 1,6 Lega PBz 6,0Sn-Cu balance
Al / L 20-40 1,6-2-2,5 At Pure 99,5% To the
Sn / L 2-2,5 Sn Puro Sn 99,9%
AlMg5 / L 2,5 Orientation Al-Mg Mg-5% Al saldo
LMSn / L 2,5 Orientation SN 89%, Sb7, 50%, 3.50% Cu
Ms / L 1,6 Orientation Cu-Zn Cu63%-Zn saldo
AlBz9Mn / L 160-180 1,6 Super Orientation 8,5Al 2 Cu-50Mn saldo
Orientation Cu-Zn 1,6 Orientation 68% Cu-Zn 32% e ALTR tenor
Filo Zn tutti Zn puro Zn > 99,995%
Filo Zn / Al Orientation 85% Zn-Al 15%
Filo Zn / Sn Orientation 80% Zn-Sn 20%
Gross Ella di Zn Zn puro Zn > 99,995%