The Twin Wire Arc Spraying (TWAS) system is a thermal spray process used to apply a coating of metal onto
a substrate. This method is widely used in various industries for applications that require corrosion protection,
wear resistance, electrical conductivity, or dimensional restoration of components.
How Twin Wire Arc Spraying Works
1.Wire Feed:
The process begins with two metal wires that serve as the feedstock. These wires are typically made of the coating
material, such as zinc wire, aluminum wire , or other alloys wire , depending on the desired coating properties.
2. Arc Formation:
The two wires are fed into a spray gun, where they are electrically charged with opposite polarities, creating an arc
when they meet at the tip of the gun. This arc melts the tips of the wires.
3.Atomization and Propulsion:
Compressed air or gas is directed at the molten wire tips, atomizing the molten metal into fine droplets.
These droplets are then propelled at high velocity toward the substrate, where they flatten, solidify, and form coating.
4.Coating Deposition:
The molten droplets build up layer by layer on the substrate, forming a dense, uniform coating with the desirethickness.
Applications of Twin Wire Arc Spraying
1.Corrosion Protection:
Zinc and aluminum coatings are commonly applied to steel structures, such as bridges, marine components,
and pipelines, to provide sacrificial protection against corrosion.
2.Wear Resistance:
Harder materials, such as nickel-based alloys or stainless steel, can be sprayed to create wear-resistant surfaces
on machinery, tools, and engine components.
3.Dimensional Restoration:
Used to repair worn or damaged parts by building up the worn surface with a new layer of metal, restoring the
component to its original dimensions and specifications.
4. Electrical Conductivity:
Coatings of conductive materials, such as copper or aluminum, are used in electrical and electronic applications
for conductive paths or electromagnetic shielding.
