Operating parameters which affect the droplet generation characteristics for a single wire arc spray, SWAS, torch have been studied. The droplet size distribution, velocity, axial divergence, and deposition efficiency can be controlled by the selection of wire size, wire feed rate, arc voltage, and gas jet back pressure. Coatings have been formed under a variety of operating conditions with structures from 3 mm to 4.5 mm in width. The average deposition efficiency is greater than 80 % and the average axial divergence angle is 2.4°. The SWAS torch has been shown to operate for extended periods of time with minimal erosion of non-consumable electrode.

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