Twin Wire Arc Spray
Twin Wire Arc Spray coatings deliver long-term corrosion protection using aluminum and zinc alloys for industrial and marine applications. Located in Alberta, serving internationally, we have been the trusted applicators for industry leaders for over 35 years. Contact us to discuss your project and request a quote.
What Is Thermal Sprayed Aluminum (TSA) Coating?
Thermal Sprayed Aluminum coatings (TSA), also referred to as metallizing, are specialized protective coatings designed to guard against corrosion and extend the lifespan of critical assets. Using aluminum, zinc, or zinc-aluminum blends, TSA coatings are applied by melting the metal in either powdered or wire form and propelling it onto the surface of a structure. This creates a durable sacrificial barrier that protects the underlying steel. In addition to corrosion resistance, TSA can also improve wear resistance, traction, and restore original dimensions to worn components. Among the thermal spray processes available, Twin Wire Arc systems and Combustion Wire Fed (flame spray) systems are recognized as the most effective for applying TSA.
Twin Wire Arc Spray Technology
Of the available application methods, Twin Wire Arc Spray is the most productive and cost-effective, offering higher deposition rates than other coating systems. This process energizes two conductive wires with DC power, one positive and one negative, which meet in a gun head and arc against each other. The arc melts the metal, creating coating material that is propelled onto the substrate.
One major advantage of Twin Wire Arc Spray is its low heat application, with surface temperatures kept as low as 65 °C. This ensures no metallurgical damage or distortion while making it possible to rebuild worn areas back to their original dimensions. The coatings, which typically use aluminum, zinc, or zinc-aluminum alloys, act as anodic layers that sacrifice themselves to prevent steel corrosion. While arc spray coatings are naturally porous, sealers can be applied to slow the galvanic dissolution process and enhance long-term performance.
When sealed properly, these coatings can provide 50 years or more of corrosion protection, surpassing traditional galvanizing. Aluminum and zinc-aluminum alloys, in particular, offer strong resistance in aggressive environments, maintaining structural integrity while offering sacrificial protection.
Common Industrial Paint Coatings Applications
Thermal Sprayed Aluminum coatings provide a range of high-performance benefits that go beyond basic corrosion protection. Unlike conventional paint systems, TSA creates a metallurgically bonded layer that enhances durability in ways other coatings cannot. Some of the unique advantages include:
- Excellent long-term resistance to atmospheric and marine corrosion.
- Low application temperature prevents heat distortion or metallurgical changes in steel substrates.
- Easy repair and rebuild capability for worn or corroded surfaces.
- Compatibility with sealers to extend service life even further.
Industrial Benefits & Applications of Arc Spray Coatings
- Prolongs the lifespan of parts.
- Provides anti-fretting and anti-galling protection.
- Enhances structural integrity and durability.
- Reduces downtime, maintenance, and replacement costs in facilities.
- Protects equipment used in marine applications that are constantly immersed or submerged in seawater.
- Offers strong chemical resistance.
- Extends the lifespan of public-use structures including bike paths, playground equipment, and utilities.
- Reduces heat transfer
- Improves fatigue strength in stressed components.
- Protects against cavitation damage on pumps and hydraulic parts.
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Twin Wire Arc Spray – Thermal Sprayed Aluminum Coating FAQs
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Twin Wire Arc Spray uses two energized wires that arc against each other to create molten material, which is then sprayed onto the surface. It offers higher deposition rates, lower costs, and more consistent coverage than many other thermal spray processes.
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TSA coatings provide longer-lasting corrosion protection (often 50+ years), resist high temperatures, prevent distortion due to their low-heat application, and can be sealed for even greater durability. Unlike paint, TSA creates a metallurgically bonded layer that does not peel or flake.
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Common industries include offshore oil and gas, marine, energy, infrastructure, utilities, and manufacturing. Applications range from pipelines, offshore platforms, and ship hulls to bridges, tanks, playground structures, and bike paths.