Thermion Frequently Asked Questions

The process of taking material in the form of wire, rod, or powder made of either metallic or non-metallic makeup and heating it with gas or electricity, and then propelling it onto a substrate to create a coating.

HVOF or High-Velocity Oxy-Fuel, Plasma Spray, Power/Wire/ Rod Flame Spray, Detonation Flame Spray, Cold Spray and Twin Wire Arc Spray

Metalizing is a generic term used to describe all processes under Thermal Spray.

Twin wire arc spray or electric arc spray utilizes energy produced by a power supply (welder) to energize two conductive materials, one positive and the other negative. These two wires meet at a gun head where they arc against themselves; at this point, the material becomes molten. Dry compressed air is used to both atomize and propel the particles to the substrate. Note, once the particles leave the arc zone, they start to solidify and thus are in a semi-molten state.

Arc spray uses two wires, which lends itself to be more than twice or more productive than other thermal spray processes. Arc spray also needs only dry compressed air and electricity, making it significantly more economical to operate than other costly thermal spray processes.

Any conductive material in wire form can be sprayed using Twin Wire Arc Spray. For years, there have been a plethora materials available in solid wire form. Further to this, the advance of cored wires has created endless possibilities of wire compositions for wear, abrasion, and corrosion, to name a few.

Thermion is a worldwide leader in Twin Wire Arc Spray Equipment manufacturing. Back in the early 80s, Frank Rogers invented his technology for arc spraying, thus kick-starting Thermion into a major manufacturer of Arc Spray equipment.

YES, all of Thermion’s equipment and parts are manufactured right here in the USA at Thermion’s facilities.

YES Thermion maintains a considerable amount of wire inventory in stock of everyday used materials, with specialty wire only being a day or week out.

Yes, Thermion has decades of experience in arc spray and gladly shares this wealth of knowledge and techniques.