Arc spray vs flame spray; they are two different types of thermal spraying coatings. With a lot of similarities between the two, it is quite hard to distinguish between them as the capabilities of the two techniques overlap.
As a business that is looking to utilise the unique techniques of thermal spraying, it can be difficult for you to decide which is the best coating solution for your sector and application.
You may have heard of Arc spray and flame spray, but do you know the similarities and differences? In this Alphatek blog, we are going to look at some of the major differences between arc spray and flame spray, so that you can better understand them when you need either one of them or both.
What Is Arc Spraying?
This spraying method is arguably the process with the highest productivity. It utilises an arc point which is created between two wires and then electrically conductive. Melting will occur at the point where the wires connect. The arc allows for heating which in turn creates deposition and melting, like flame spraying which is used with a torch. Compressed air will be used for spraying the coatings. This procedure is popular due to its cost-effectiveness and will typically use aluminium or zinc as the base material.
What Is Flame Spraying?
Flame spraying is an excellent option for surfaces which aren’t designed to handle extreme stress. The coating which results from this process is not strongly attached to the surface since the spraying mechanism is powered by a lower flame velocity. The flame will be generated via oxygen which has been combined with fuel, and this will melt the mixture. Combustion flame spraying is popular for low-intensity applications due to its low cost.
What Are The Differences between Arc Spray And Flame Spray?
The differences and the reason for choosing either Arc spray or flame spray fall into three categories – operating, technical and personal preference.
However, before considering these two factors, keep in mind the capital costs of both the thermal sprays. Capital costs of flame spraying are typically lower than arc spraying but the running costs are typically higher. The amount of material that can be sprayed by the flame spray process is limited by the size of the wire and the material being sprayed.
Arc Spray Vs Flame Spray: Operating Principles
The main difference lies in the way 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.
Arc spray, 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, which are fed into the spray gun by drive rolls.
Arc Spray Vs Flame Spray: Technical Viewpoint
From a technical viewpoint, Arc spray coatings have a higher bond strength than flame spray. If your business or application requires a coating with a greater bond strength, Arc spray is the perfect option between the two.
However, the bond strength capabilities of a flame spray coating are still more than the needs of the application. In many cases, some applications are specified that coatings must be arc sprayed.
Another technical reason is the availability of power with flame spraying being more portable than arc spray. The final main technical consideration is the required spray rate where the arc can be much greater than flame.
Arc Spray Vs Flame Spray: Personal Preference
From a personal point of view and working with a variety of people over the years, some people just don’t like working with naked flames. Whether that be personnel or business-wise it also requires more skill to operate.
Nothing a day’s training can’t fix. But from a business viewpoint, flame spray requires more focus on risk assessments, safety, and insurance. Arc spray can be applied at a lower temperature and is easier to coat large areas at a time.
Contact Us
We have an unparalleled experience. Here at Alphatek, we have a combined 100+ years of cumulative coating expertise in-house. We hope we have covered everything between Arc Spray Vs Flame Spray for you to gain a greater understanding of which will best suit your business and applications.
If you haven’t, we’ve got you covered. For Metal Spraying and Thermal Spray Coating specialists, look no further than us, Alphatek. You can call us directly on 01706 821021, or you can email us at postbox@alphatek.co.uk.
Alternatively, if you’d like to visit us, we are located 20 miles north of Manchester. Just be wary of our opening times.
