An experimental study of twin-wire electric arc spraying of zinc and aluminum coatings demonstrates the suitability of the process for anticorrosion applications. Experiments were conducted using Box-type full-factorial designs. Operating parameters were varied around the following process parameters: nozzle diameter, nozzle geometry, and system pressure. A systematic design of experiments displayed the range of processing conditions and their effect on the resultant coatings. The coatings were characterized with hardness and deposition efficiency tests, and optical metallography. Coating properties are quantified with respect to roughness, hardness, porosity, thickness, bond strength, and microstructure. The features of the coatings are correlated with the process changes. Selected analytical calculations and process diagnostics of the meltpool dynamics are presented.

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