Arc Spray

Arc spray or sometimes referred to as twin wire arc spray, is a process that uses an electric arc to melt wires.  The molten metal is then atomised with compressed air to create a spray stream that applies the coating onto the surface being sprayed. Anti-corrosion or engineering coatings can be applied by arc spray and changing between the two is quite simple.  Arc spray systems are commonly considered to be easy to operate and also to automate.



Heat Source: Electric arc

Material: Wire

Transfer: Compressed air

Process: Two wires are fed into the pistol and electrically charged, one positive and one negative. The wires are forced together and form an electric arc, melting the wire. Compressed air, passing through a nozzle, atomises the molten metal and sprays it onto the work piece. 


ARC150/S500-CL

In response to feedback from customers for a flexible system but with higher throughput, Metallisation have created the 500Amp, ARC150/S500-CL arc spray system. The ARC150 system offers a great balance of controllable throughput with flexible operation and the opportunity to have extended supplies packages up to 50m from the energiser to the pistol.
A number of new features are included to enable reliable spraying at 500A, 100% continuous duty cycle. These include a new pistol front end with contact tips instead of solid tubes; uprated supplies / cooled conductors and terminals; a heavy duty drive unit with new, v-shaped rollers; heavy duty flexible drive and a new 500A energiser with high specification digital meters. These features combine to give a flexible, reliable and manageable solution for medium and large scale thermal spray applications, producing quality, fine surface finish coatings.
The ARC150 system is designed for anti-corrosion applications spraying zinc, aluminium and their alloys but can also be used to spray other materials commonly sprayed in larger applications such as high temperature alloys.

Key features

  • 500A capacity = high productivity
  • Closed-loop current = simplicity / reliability
  • Uses 2.3mm anti-corrosion wires
  • 1.6mm setup for high termperature alloys
  • Air cooled cables = lightweight
  • Flexible pistol manoeuvrability
  • New 500A energiser with digital display
  • 10 and 20m supplies packages (max wire feed)
  • Extension supplies to extend up to 50m
  • Easy to setup and maintain = high productivity
  • MIG, hardboard reel and drum dispense
  • New heavy duty drive unit and rollers
  • New contact tips = reliability at higher current
  • 100% duty cycle = reliability and productivity

ARC145/S245 & S345-CL

Metallisation's desire for continuous improvement, alongside customer feedback has led to the development of the latest range of ARC145 systems. The systems combine the best elements of the proven ARC140 system and the more recently released ARC150 system.
The ARC145 pistol utilises the latest in design of contact tips and air-concentrator. The head design, along with the contact tips improves cooling to the arc area, resulting in longer contact tip life and more reliable operation when spraying for extended periods of time. The improved airflow and more efficient arc also allow the system to produce a finer coating without compromising deposit efficiency. The new tips, manufactured from a hard wearing, copper alloy are quick and easy to change. The new material, along with improved cooling help to enhance tip life considerably and reduce downtime and running costs.
The ARC145 pistol also includes other enhancements such as measuring the spray voltage at the pistol (assisting diagnostics and simplifying setup) and more simple, robust push buttons. A small amount of weight is taken out of the pistol compared to the ARC140 and a more robust control cable connection is also introduced. Reversible (twice the life) V-rollers complete the ARC145 pistols new features and ensure the most reliable wire feed possible.
The reversible V-rollers also feature on the new ARC145 wire drive unit which utilises the proven technology from the ARC150 spray systems. A larger motor, inverter and independent tension drive unit gives the very best in reliable and repeatable wire feeding.
The new drive unit and pistol are still joined with Metallisation's patented ‘Synchrodrive’ principle. The flexible drive cable in 5m, 10m, and 20m lengths, combined with the V-rollers and more positive drive unit ensure the ultimate performance and reliability of wire feeding. The ARC145 system has been extensively tested with a range of coating wires and proven to give excellent performance over 20m feed lengths with the most challenging, cored engineering wires.
The energiser range includes the latest enhancements introduced to the range at the start of 2016. 
  • The latest version of PLC is fitted ensuring long future proofing and support.
  • Digital gauges offering both scale and numeric displays.
  • MCB’s are fitted to the incoming power supply as additional protection if the correct fusing is not fitted to the electrical supply.
  • New Data Kit option giving the possibility of remote monitoring and logging of certain energiser data at a customer’s HMI via a Siemens S7-1200 series CPU.
The system is designed for demanding engineering and anti-corrosion applications and is the most flexible arc spray machine. Suited to hand held or robotic mounting, it is as happy spraying 1.6mm engineering wires onto shafts as it is spraying 2.3mm corrosion coatings onto steel fabrications. The system has undergone a rigorous design, engineering and testing program to bring you a high quality, medium capacity but flexible system that will aid you to maximise production, efficiency and productivity in your thermal spray operations.

Key features
  • New S245-CL or S345-CL sealed energiser = reliability
  • Contact tubes/tip = fine coating, long life
  • Digital displays = clear, robust with wide viewing angle
  • Closed-loop current = simplicity / reliability
  • Uses wires from 1.6mm to 2.3mm
  • Air cooled cables = lightweight
  • Excellent pistol manoeuvrability
  • 5,10 and 20m supplies packages
  • Anti-corrosion and engineering coatings
  • Easy to maintain = lower downtime
  • 5m pull option available for small workshops
  • MIG and drum dispense
  • Soft start for smooth start ups = reliability
  • PTFE lined conduits = reliable long wire feed
 

ARC170/AC-CL

The ARC170AC arc spray variant has been developed with air cooled cables for a lighter hand-held pistol weight when spraying at 700A. The use of air cooled cables, as well as some other pistol modifications have reduced the hand held weight by about 2kg – a significant benefit to the spray operators.  Feedback from users of the existing 700A push systems is that the pistol is less restricted in movement and lighter than the systems that they are used to. This, combined with the ability to have 10m push/pull and even longer extended supplies systems is making the ARC170AC a great solution for large scale anti-corrosion applications. As an additional development, the drive motor is now a powerful brushless AC motor with inverter control.
The Metallisation ARC170AC offers high throughput with large diameter wires of 1/8” / 3.2mm and 3/16” / 4.76mm, and is the recommended system for large scale, anti-corrosion applications.  The ARC170AC's proven and patented Synchrodrive push/pull system has no motor in the pistol, resulting in a lighter, more maneuverable hand-held spray gun which has a 10m wire dispense distance.  The system's robust design also includes the established Constant Geometry (CG) head, which ensures a smooth and consistent spray quality.
The new S700CL, 700 amp energiser still offers high spray rates for reduced spraying times over large areas but is now combined with closed loop current control.  This enables the operator to set the spray current independent of wire type before starting the job, enabling easier setup and protection of the system from over-current.  The control function is now controlled by a simple PLC which ensures improved reliability as less component parts are required.  It also makes fault finding simple using a standard multimeter with the I/O for the PLC.
The S700CL energiser also features sealed electronics for excellent reliability in the harshest of spray environments.  The design also allows for multiple customer-specific packaging options for the wire drive and dispense.  In one option, for example, the unit is neatly mounted on the energiser, leaving it free to swivel and follow the operator when spraying.  Other options include floor or trolley mounting of the wire drive unit.
 
Key features
  • 10m wire drive = great spraying range
  • 10/15m supplies extension options
  • 700A, 100% duty cycle = reliable
  • Closed loop current = simplicity / reliability
  • 3.17/4.76mm wires = high throughput
  • Air-cooled cables = lightweight / flexible
  • Flexible pistol movement
  • Easy to maintain = lower downtime
  • MIG, hardboard reel or Drum dispense
  • Zinc, Alumininium or Zinc/Aluminium alloy

ARC701-CL

The Metallisation Arc701-CL twin wire arc spray system is a unique blend of ability and innovation. It brings together the proven performance of our Arc700 pistol plus the very latest technological advances. For instance, the 700A energiser still offers high spray rates for reduced spraying times over large areas but is now combined with closed loop current control. This enables the operator to set the spray current independent of wire type before starting the job, enabling easier setup and protection of the system from over-current. 
The control function is now controlled by a simple PLC which ensures improved reliability as less component parts are required. It also makes fault finding simple using a standard multimeter with the I/O for the PLC. The S700CL energizer features sealed electronics for excellent reliability in the harshest of spray environments. 
The design also allows for multiple customer-specific packaging options for the wire drive and dispense. In one option, for example, the unit is neatly mounted on the energiser, leaving it free to swivel and follow the operator when spraying. Other options include floor or trolley mounting of the wire drive unit.
The drive unit is very robust, ensuring supreme reliability in the most arduous of site conditions. The lightweight, hand-held pistol incorporates proven Metallisation technology, including a unique, constant geometry (CG) head. This ensures smooth and consistent spray quality and minimal downtime when changing consumable spares. Various packaging options, including an extended site trolley, allow the energiser to be sited up to 25m from the pistol spraying area. Alternatively, the drive unit can be mounted neatly on the energiser, leaving it free to swivel and follow the operator when spraying.
 
Key features
  • Closed-loop current = simplicity / reliability
  • New sealed energiser = reliability
  • High throughput = less spray time
  • Easy to maintain = lower downtime
  • Uses wires from 2.3mm to 3.17mm
  • Push system
  • Drive to pistol distance = 5m
  • Energiser to pistol distance up to 25m
  • Designed and suited for anti-corrosion applications
  • Lightweight pistol
  • Robust design = greater reliability
  • Wire dispense from reels, coils or drums

ARC528

The Metallisation ARC528E-ICC arc spray systems, with either the 250 amp or 350 amp energiser, offers the ultimate in reliability and precision for demanding production applications. This includes both anti-corrosion and engineering coatings. Wire drive is supplied at the heavy-duty pistol by a highly accurate, powerful DC servo motor, driving a robust gearbox and drive roller system. 
The high performance pistol incorporates proven Metallisation technology, including a unique constant geometry (CG) head. This ensures smooth and consistent spray quality and minimal downtime when changing consumable spares. 
A new addition to the 528E system is the quick release supply package option. To further reduce machine downtime, the supplies package can be chosen with a quick release option, enabling the pistol to be removed quickly from the line and either maintained or exchanged for a spare pistol for preventative maintenance routines. 
The PLC controlled energisers enable the operator to set the spray current independent of wire type before starting the job, enabling easier setup and protection of the system from over-current. The control function is now controlled by a simple PLC which ensures improved reliability as less component parts are required. It also makes fault finding simple using a standard multimeter with the I/O for the PLC. All of the control electronics are in a sealed area of the energiser to protect them from the often harsh, production environment. 
The 528E-ICC is offered with either the 250 amp or 350 amp energiser, depending on your production and throughput requirements. As an alternative, a high throughput version is also offered with either 700 amp or 1000 amp energisers. 
 
Key features
  • New S250 and S350 sealed energisers
  • Closed Loop Current = simplicity / reliability
  • Inbuilt pistol control system
  • Integrates to production machinery
  • Safety interlocks
  • Anti-corrosion and engineering wires
  • Easy to maintain = lower downtime
  • Uses wires 1.2mm to 3.17mm
  • Quick release supplies option for fast pistol changeover
  • Wire dispense from reels, coils or drums

ARC340-PLC

The Metallisation ARC340-PLC arc spray system is the preferred choice for general engineering applications. It is ideally suited to tool post and automation mounted applications with occasional requirements for hand spraying. The proven ARC340 pistol is now combined with a new range of PLC controlled, 250A and 350A switched voltage energisers. 
The ARC340-PLC system with a S250, 250A energiser is ideally suited to many engineering applications. However, for some larger scale applications where a higher throughput is required, the S350, 350A energiser will enable higher spray rates and increased productivity. The ARC340 is capable to spray anti-corrosion coatings also but may not be the most suitable solution for these applications. Alternative, more suitable systems could be the ARC140, ARC701 or ARC170 systems. 
The PLC controller within the sealed electronics area of the energiser enables easy fault finding and offer over-current protection for the system. This means that the system will protect itself in the event of operator error when setting up spray parameters. The ARC340 pistol on its own supersedes and can be fitted as a direct replacement to the ARC234, ARC240 and ARC375 pistols. With fairly minimal modifications, it can also be fitted to some competitor pull systems.
 
Key features
  • PLC controlled energisers = reliabilty
  • Over-current protection
  • Air driven pull system
  • Air cooled or solid cables
  • Easy to maintain
  • Uses wires from 1.6 - 2.3mm dia. without changing feed rollers
  • Choice of coating textures
  • Optional Arcbeam spray concentrator
  • Optional deflected spray extension sections

MEC 96/600

The MEC 96/600 system is a 3 phase, 600 amp arc spray system with 5 metre pull via a pneumatic drive in the pistol. It can be set up to spray 1.6mm engineering wires or 2.3mm anti corrosion wires.




TMS BRIDGEMASTER

 

The TMS Bridgemaster is a heavy duty, lightweight, low energy, high deposition arcspray system for applying metalized coatings. Designed for shop or field applications, the Bridgemaster is a proven workhorse in any environment. Meters and controls are conveniently located on the feeder providing "at the workplace" control. Flexibility in design allows for a wide variety of possible configurations. For shop or field corrosion control coatings, the Bridgemaster system is a formidable package. The lightweight portability of the total system, low maintenance, lightweight gun and leads, and the "no wire-clipping" feature add up to increased arc production time for the applicator. Sprays 3.2mm and 4.76mm wires, wide spray pattern, powered by single phase or 3 phase inverters or DC welding power supplies.



Many other systems & combinations available. We also service and stock parts for other brands such as Thermion, Tafa, Metco -  contact us with your enquiry.