Simultaneously Spraying of Different Wires by Twin Wire Arc Spraying Using Adapted Air-Caps and Shroud Effect

In this study, different air-cap configurations and shroud designs are developed and tested in twin wire arc spraying (TWAS) trails with the intent of increasing the collision probability of in-flight particles and thereby controlling coating composition and microstructure. In order to obtain greater insight on alloying effects and a better understanding of the coating build-up process, solid nickel and solid iron wires are used as feedstock materials and simultaneously sprayed on medium carbon steel substrates. The effect of polarity reversal and the use of a secondary atomization gas are also assessed. Detailed test results are presented in the paper along with in-depth analysis.