Wire arc spray is a form of thermal spraying where two consumable metal wires are fed independently into the spray gun. These wires are then charged and an arc is generated between them. The heat from this arc melts the incoming wire, which is then entrained in an air jet from the gun. This entrained molten feedstock is then deposited onto a substrate. This process is commonly used for metallic, heavy coatings.
Another feature of this process is that it allows for the feeding of different metal wires simultaneously through each electrode to produce pseudo-alloys.