Typical Arc Spray Installation In the arc-wire process, two consumable wire electrodes that are insulated from each other automatically advance to meet at a point in an atomizing gas stream. A powerful electrical current is applied across the wires starts an arc that melts the tips of the wire electrodes. An atomizing gas stream, usually compressed air, is directed into the arc zone, shearing off molten droplets that form the atomized spray.

Typical Arc Spray Head Wire electrodes are fed through wire guides and into the contact tips. The atomizing nozzle conducts the compressed air and directs it across the arc zone. Insulated power cables connect the gun to the DC power source. Arc guns also include mechanisms for feeding the wire at a controlled rate. Contact tips are sized for a particular wire diameter. A trigger switch on the gun controls the wire feed, compressed air supply, and electric power.