Thermal sprayed zinc and aluminum coatings have proven to be very effective for corrosion protection of steel in infrastructure and a wide variety of other industries [1]. Strong competition from other processes, such as galvanizing or painting, has put a major emphasis on maximizing the efficiency and resulting economics of thermal spraying for these markets. Wire arc spraying has seen increasing use for anti-corrosion due to its high spray rates, low operating cost and excellent coating quality. The goal of this study was to examine the factors which influence the efficiency of arc spraying for zinc and aluminum coatings, leading to the development of a specialized arc spray system which maximizes this efficiency.
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