The high potential of wire spraying processes for the manufacturing of high quality coatings has been confirmed. In addition to compact wires tube and grooved cored wires can be processed by arc and HVCW spraying. The investigations with concern to the melting off behavior during HVCW spraying show a significantly more continuous melting off for compact and tube cored wires in comparison to grooved cored wires. During arc spraying no significant difference depending on the wire design is observed. Further investigations with regard to the melting off behavior will deal with the influence of straightening of the wire. Additionally the boundary conditions with respect to fluid dynamics will be optimized.
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