Call Us Today: 877-884-3428

Arc Spray Equipment & Systems

Corrosion Control Large Diameter Wires

Arc Spray Equipment

High production Thermion® Arc Spray Systems using either 3/16 or 1/8 dia. aluminum, zn/al, or zinc. These units are designed to be used in portable field applications such as bridges, water tanks, transmission towers, wind mills, light poles, etc., where access is limited and turnaround times are short.

  • Precision Arc 3.2 Anti Corrosion- Moderate Production - Though put production rates of up to 80 lbs. of material an hour over 160 sq. ft. at a thickness of +/- 10 mils.
  • Precision Arc 4.8 Anti Corrosion - High Production - Though put production rates of up to 189 lbs. of material an hour over 472 sq. ft. at a thickness of +/- 10 mils.
  • Precision Arc 5.0 - Highest Production, Low Energy! Thermion's Newest Model - Designed to combat dust. Uses spraying wire of diameter 3/16" (4.8mm) for very high deposition rates of 70% DE at 700 amperes and 100% duty cycle even in high demand robot or machine automation, or up to 1000 amperes in most manual spraying operations.

Click here to see a live demo of these high production machines.

Engineered Coatings / Hardwires Both Solid and Cored

The AVD series units are ideally suited to spray hardwires for use in electrical, anti-fretting and wear, reclamation of dimension, clearance control and environmental applications used in manufacturing and remanufacturing. Our unique AVD technology allows for successful spraying of 1/16", 2 mm, 3/32" aluminums, bronzes, chromes, nickels, stainless, tungsten, etc. Our most recent advancements allow for the spraying of 1/8" dia. hardwires. This will double, if not triple, the production rates experienced previously in these specialized industries.

  • AVD 250 - Thermion's newest AVD spray system - Designed specifically as an economical solution for applications with lighter production needs. Intended for shops that metalize as a sideline business as well as startup operations.
  • AVD 350 - Engineering Coatings, Anti Corrosion, Restoration - Normal Production - Though put production rates of up to 20-30 lbs. an hour using 1/16" or 3/32" dia. solid or cored hardwires.
  • AVD 450 - Engineering Coatings, Moderate Production - Anti Corrosion, Restoration - High Production - Though put production rates of up to 80 lbs. of material an hour using1/16", 3/32" or 1/8" dia. solid or cored hardwires.
  • AVD 456HD- Power Supply: ( N/S) Conventional 450 Amp. Incoming power; 3 phase multi Voltage at 60 Hz. Wire Capabilities: All Conductive Wires; 1/8 (3.2mm), 3/32;" (2.3mm), 2mm or 1/16;" (1.6mm)

Mini Arc Spray Unit

Mini Arc Spray Unit

Our AVD 150 will readily spray aluminum, zn/al, and zinc. This compact unit weighs about 35 lbs. and can easily be moved around either the worksite or shop by a single person. Used for small area touch up, field welds, galvanizing repair, automotive restoration, etc. Designed to use a minimal amount of services by way of air (20 cfm) and incoming power (single phase).

  • AVD 150 - Automotive Restoration; Touch Up Field/Shop Work - Set to spray 1/16" dia. material.

About Metalizing Technology Used in Thermion® Arc Spray Systems

Thermion's exclusive inventions for thermal spraying (metalizing) improved the twin wire arc spray coating metalizing process in coating quality, productivity, portability, and adaptability.

  1. High Deposition Metalizing - Maintains 70% deposit efficiency while spraying zinc at 189lbs/hr (86 kg/hr).
  2. Arc Shorting Control - This technology was patented due to its unique ability to control arc shorting in the arc spray process, therefore, maintaining a steady arc.
  3. AVD or Arc Voltage Drive - Eliminates arc shorting and automatically adjusts wirefeed to maintain a perfect arc which improves coating density and eliminates coating defects due to arc sputtering.
  4. Six Roll Drive - This drive guarantees a non-slip positive wire feed with knurled feed rollers then removes the knurl effect when feeding continues through the liners and tips.
  5. TH604 Non Slip Coatings - This coating containing both aluminum and ceramics provides long-term corrosion and wear protection for a non-slip or wear resistant coating for all substrates.
  6. Combination Leads - These leads accommodate the wire, power, and air enables the front end assembly to be light yet handle amperages necessary to perform High Deposition Metalizing/Arc Spray.
Anti-Corrosive Metalizer - Anti-Corrosion Arc Spray System

Precision Arc 3.2

The PRECISION ARC3.2 allows for trouble free spraying minimizing wire clipping.Learn More »

Arc Sprayed Zinc - Zinc Metallizing Spray - Precision 4.8

Precision Arc 4.8

The PRECISION ARC 4.8 utilizes our Arc Shorting Control technology which vaulted Thermion® to the forefront of High Production Arc Spray.Learn More »

Metal Spray System - Precision Arc 5.0

Precision Arc 5.0

The Precision Arc 5.0 is an improved spray system which incorporates all the improvements in designing, building, and maintaining hundreds of Thermion arc spray systems worldwide.Learn More »

Automotive Arc Spray System & Restoration - AVD 150

AVD 150

The AVD 150 is a miniaturized arc spray system. Often times referred to as a metalizer, metalizing, and even spray welding, it is in fact a twin wire arc spray system.Learn More »

Lighter Production Spray System - AVD 250

AVD 250

This system was designed specifically as an economical solution for applications that call for lighter production needsLearn More »

Twin Wire & Auto Arc Spray System - AVD 350

AVD 350

The patented "AVD" or Arc Voltage Drive automatically controls the motor speed to maintain a perfect arc gap which creates consistent high density coatings. Learn More »

Engineered Coating Services - AVD 450

AVD 450

The patented Arc Voltage Drive automatically controls the motor speed to maintain a perfect arc gap which creates consistent high density coatings.Learn More »

High Density Coating System - AVD 456 HD

AVD 456 HD

Preset Spring Pressure allows a continuous and precise pressure on the wires at all times and does not change when new wires are loaded. Learn More »

Custom Spray Welding Systems

Custom Spray Systems

The patented "AVD" or Arc Voltage Drive automatically controls the motor speed to maintain a perfect arc gap which creates consistent high density coatings. Learn More »

Click here to submit a Request for Quote
or call us today at 877-884-3428