The aim of this study was to point out the role of each electrode in the droplets formation in twin arc spraying. This way, two consumable wires of different properties, namely steel and copper, were sprayed simultaneously. The DPV 2000 diagnostic system was used to determine the size, temperature and velocity of in-flight particles, detected at the same locations than those previously tested on particles collection. Then, a model based on the particle temperature was developed to separate particles from the anode and the cathode wires. Results showed significant modifications in term of size, velocity, temperature and repartition when changing material electrodes. To validate the proposed model, modelling results were first compared to results found on properties of collected particles, i.e. sizes and percentages. Then, important differences of in-flight particles characteristics, velocity and temperature, were pointed out depending on the electrode nature and on radial locations in the spray jet. Finally, some coatings were sprayed at the same locations and analyzed in term of thickness. Results showed that the thickness distribution was largely dependent on the anode nature, which was in close agreements with in-flight particles analysis.

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