Skip to main content
Main Menu
  • Materials
    Back
    Materials
    • EB-PVD Ingots
    • Ekonol®
      Back
      Ekonol®
      • T101
      • M102A
    • Flexicord
      Back
      Flexicord
      • Ceramic Series
      • Ceramic Supra Series
      • Bond Coat Series
      • RocDur Series
      • Carbide Series
      • Special Alloy Series
    • PVD Sputtering Targets
      Back
      PVD Sputtering Targets
      • Molybdenum
      • Moly-based
      • Tungsten
      • Niobium
      • Tantalum
      • Silicon
      • SiAl
      • TiOx
    • RocDur Series
      Back
      RocDur Series
      • RocDur 29
      • RocDur 37
      • RocDur 40
      • RocDur 44
      • RocDur 62
      • RocDur 6728
      • RocDur 6740
      • RocDur 6750
      • RocDur Co6
      • RocDur Co 12
    • Rokide® Rods
      Back
      Rokide® Rods
      • Aluminum Oxide
      • Chromium Oxide
      • Zirconium Oxide
      • Bond Coat
    • Thermal Spray Powders
      Back
      Thermal Spray Powders
      • Yttria Zirconia
      • Yttria
      • EBC Powders
      • Zirconia
      • Alumina Titania
      • Aluminum Oxide
      • Chromium Oxide
      • Mullite
      • Spinel
      • Titania
    • Thermal Spray Wires
      Back
      Thermal Spray Wires
      • Tin
      • Copper
      • Iron
      • Nickel
    • Tuf-Cote® for Brazing
      Back
      Tuf-Cote® for Brazing
      • Grade A
      • Grade N
      • Grade GM-S
      • Green GM-S
      • Grey GM-S
      • Grade PLS
      • Grade RSL
      • Grade HR2
      • Grade WCS F/M
      • Grade WCS M67
      • Grade WCS F
      • Grade WCS M
      • Grade M
  • Equipment
    Back
    Equipment
    • Plasma Spray
      Back
      Plasma Spray
      • ProPlasma Gun
      • ProPlasma Full System
    • Plasma Transfer Arc (PTA)
    • Flame Spray
      Back
      Flame Spray
      • Z-Jet
      • Top Jet
      • Master Jet® 3s
      • Master Jet Auto
    • Rokide®
      Back
      Rokide®
      • Flame Spray Unit
      • RF Electric Drive Unit
      • RF Combustion Head
      • Flexicord Conversion Kit
      • Spray Unit-Gun Extension for ID Spray
  • Applications
    Back
    Applications
    • Corrosion protection of weld seams
    • Protection against molten zinc
    • Schoopage of film capacitors
    • Reaction barrier coating for setter plates
    • Automotive
    • Aerospace
    • Electronics and Display
    • Power Generation
    • Paper
    • Oil and Gas
    • Solar
    • Mining
    • Semiconductor
  • Resource Center
    Back
    Resource Center
    • Blog and Events
  • Sustainability
    Back
    Sustainability
    • Contact Us
    world SAINT-GOBAIN
    Logo Saint-Gobain Coating Solutions
    • Materials
      • EB-PVD Ingots
      • Ekonol®
        • T101
        • M102A
      • Flexicord
        • Ceramic Series
        • Ceramic Supra Series
        • Bond Coat Series
        • RocDur Series
        • Carbide Series
        • Special Alloy Series
      • PVD Sputtering Targets
        • Molybdenum
        • Moly-based
        • Tungsten
        • Niobium
        • Tantalum
        • Silicon
        • SiAl
        • TiOx
      • RocDur Series
        • RocDur 29
        • RocDur 37
        • RocDur 40
        • RocDur 44
        • RocDur 62
        • RocDur 6728
        • RocDur 6740
        • RocDur 6750
        • RocDur Co6
        • RocDur Co 12
      • Rokide® Rods
        • Aluminum Oxide
        • Chromium Oxide
        • Zirconium Oxide
        • Bond Coat
      • Thermal Spray Powders
        • Yttria Zirconia
        • Yttria
        • EBC Powders
        • Zirconia
        • Alumina Titania
        • Aluminum Oxide
        • Chromium Oxide
        • Mullite
        • Spinel
        • Titania
      • Thermal Spray Wires
        • Tin
        • Copper
        • Iron
        • Nickel
      • Tuf-Cote® for Brazing
        • Grade A
        • Grade N
        • Grade GM-S
        • Green GM-S
        • Grey GM-S
        • Grade PLS
        • Grade RSL
        • Grade HR2
        • Grade WCS F/M
        • Grade WCS M67
        • Grade WCS F
        • Grade WCS M
        • Grade M
    • Equipment
      • Plasma Spray
        • ProPlasma Gun
        • ProPlasma Full System
      • Plasma Transfer Arc (PTA)
      • Flame Spray
        • Z-Jet
        • Top Jet
        • Master Jet® 3s
        • Master Jet Auto
      • Rokide®
        • Flame Spray Unit
        • RF Electric Drive Unit
        • RF Combustion Head
        • Flexicord Conversion Kit
        • Spray Unit-Gun Extension for ID Spray
    • Applications
      • Corrosion protection of weld seams
      • Protection against molten zinc
      • Schoopage of film capacitors
      • Reaction barrier coating for setter plates
      • Automotive
      • Aerospace
      • Electronics and Display
      • Power Generation
      • Paper
      • Oil and Gas
      • Solar
      • Mining
      • Semiconductor
    • Resource Center
      • Blog and Events
    • Sustainability
    • Contact Us

    You are here

    1. Home
    2. Blog and Events
    3. Flame Spray vs Twin Wire Arc Spray: What’s the Difference?

    Flame Spray vs Twin Wire Arc Spray: What’s the Difference?

    June 10th, 2021

    Flame spraying and twin wire arc spraying (generally referred to simply as "wire arc spraying") are two different types of thermal spraying process. With a great deal of overlap in the capabilities of these two techniques, it can sometimes be difficult to know which one is best suited to a given use case. In this article we take a look at the unique characteristics of each technique, to help you decide which is the best coating solution for your applications.

    The term “thermal spraying” encompasses a wide range of different techniques, all of which share the same fundamental operating principle: By heating a feedstock of deposition material – often in wire or powder form – and accelerating molten or semi-molten droplets of it towards a substrate, a coating can be formed. Thermal spray is used to coat structures and components with a diverse range of metals and ceramics to provide protection against corrosion, friction, or other harsh operating conditions.

    Flame spraying and wire arc spraying were the first thermal spraying techniques to be invented. They remain the simplest and most common types of thermal spraying.

    Operating Principles of Flame Spraying and Wire Arc Spraying

    The fundamental difference between flame spraying and wire arc spraying is the means by which heat is supplied to the feedstock material. Flame spraying – as the name suggests – uses a flame to do this, usually a combination of oxygen and either acetylene or propane. Deposition material is introduced to the flame in either wire or powder form, and a stream of compressed air accelerates droplets of the molten deposition material toward the substrate to coat it.

    Wire arc spraying, on the other hand, uses an electrical arc to heat the feedstock material. The deposition material is always supplied in the form of two wires (hence the name “twin wire arc spraying”), which are fed into the spray gun by drive rolls. Within the spray gun, a potential difference is applied between the two wires such that electrical arcing takes place. This causes the tips of both wires to melt. A high-speed flow of gas removes molten material from the wire tips and accelerates it toward the substrate, while breaking down larger droplets into smaller ones.

    Practical Differences Between Flame Spraying and Wire Arc Spraying

    The operational differences between flame spraying and wire arc may seem minor: both techniques involve the application of heat and compressed gas to the deposition material to melt it and spray it toward the substrate. However, the different operating principles have several practical ramifications.

    Flame spraying and wire arc spraying offer different performance. Wire arc spraying can offer higher deposition rates (provided equipment is capable of delivering sufficiently high power); lending it to applications where speed is important. However, flame spraying has the advantage in a number of other performance areas: flame spraying can offer better process control leading to more stable quality, less oxidation – especially important in application where conductivity of the metal is imperative (copper, zinc) – and denser coatings suitable for demanding anti-corrosion applications. In addition, flame wire spraying offers higher deposition efficiency than wire arc spraying, meaning less loss of material leading to lower cost per mass of coating and evening out the difference in deposition rate. An important EHS favoring flame spray is the drastically lower amount of fine particle emissions, which are cut down to 1/60th compared to arc spray [1] directly leading to decreased risk of metal fume fever.

    The simplicity of flame spraying typically means it has lower capital costs than wire arc spraying. However, the running costs of flame spraying are generally higher due to the need for fuel gases. Often, the choice between flame and arc spraying can be determined by a lifetime cost analysis and the surface geometry: smaller surfaces benefit from the narrow spray stream and less overspray of flame spray, while larger ones benefit from the speed of arc spraying.

    Whether flame spraying or wire arc spraying, Saint-Gobain offers a comprehensive range of coating technologies and materials to help you achieve the result you need. To find out more about our coating solutions, get in touch with Saint-Gobain today.

     

    [1] Bémer D. et al., Ultrafine Particles Emitted by Flame and Electric Arc Guns for Thermal Spraying of Metals, The Annals of Occupational Hygiene, Volume 54, Issue 6, August 2010, Pages 607–614

    Saint-Gobain Coating Solutions is a business of Saint-Gobain Ceramic Materials

     

    Materials
    Equipment
    Application
    Technical Articles
    Contact Us
    Blog & Events
    About Us
    Resource Center
    Site Map
    Legal
    CATSCA

     CONTACT US

     

      FOLLOW US

    © Copyright Saint-Gobain 2020. All rights reserved.