AT 400 Electric Arc System

System Operation

An electric arc wire system uses an arc created between two wires to generate heat from the high current of the arc. This is the heat source, with an estimated temperature of 20,000°F, to melt the material to be sprayed. The material to be sprayed is in the form of two wires that are fed together with the wire contact guides inside the gun. Once it is melted in the arc, the liquid metal is atomized with compressed air that is injected around the arc. The atomized molten metal now forms a columned stream, similar in appearance to a spray paint pattern, except this is molten metal. The molten stream of metal is deposited on the component to be coated at a thickness of .0005" (.0127mm) per pass to .003" (.0762 mm) per pass. The variation of thickness per pass is depended on the material being sprayed and the amount of heat build up on the part being coated.

High temperature enhances bond strength.

Studies have shown that the bond strength from the electric arc is excellent due to the high temperature of the molten particles. 

A Push System saves money.

The normal dirt and grit associated with being in close proximity to the thermal spray gun is eliminated by having the wire feed motor and the wire drive system remotely contained in an all metal enclosed wire control box. This saves money in that the amount of maintenance is greatly reduced because the amount of normal wear and tear on the drive system is greatly reduced.

A push system is more safe.

In addition, an extra benefit is the weight gun drastically reduces operator fatigue, thus increasing operator productivity. The competitors 8830 weighs over 10 pounds not only creates a fatigue problem for the operator; but also a safety concern. Let's face it, there are many applications that it is just much easier to have the operator hand spray a part instead of programming a robot or investing time into a machine set up. The competitor has taken the position that all thermal spray operations should be a machine mount, thus there is no need for a light weight gun. I admire their marketing strategy to take an inherent weakness in their gun and turn it into a benefit.

If it makes sense to automate a specific product line, the heavy gun from the competitor requires a significantly larger robot to handle the additional weight.

An electric wire feed system is more consistent than an air driven one.

Other systems require compressed air to control the wire feed motor. The AT 400 uses the undeniable more consistent electronic motor control system to consistently feed the wire to maintain the correct voltage and current.

Digital Meters give you superior ability to monitor and control your process.

The AT 400 has digital meters that measure and display the voltage and current on a digital monitor. This also gives the ability to control the process from a remote location. The AT 400 allows manual operation for small jobs and allows digital control for the bigger jobs that it makes sense for.

Digitally encoded motors can be added to the AT 400 for completely automated systems; try that with an air driven motor.

Our contact tips and wire feed rolls lower maintenance costs.

You can if the maintenance is minimal and does not require tools. The wire contact tips with the AT 400 slide in place without the need of any tools. The tips in the AT 400 can be rotated 90 degrees after the have the typical groove worn into them. This doubles the life compared to the screwed in version that the competitor sells. Additionally, the wire feed rolls in the control box can be changed without tools. Switching from 14 gauge to 11 gauge is very quick and requires no tools.

All rectifiers are not created equal.

The AT 400 is capable of 15 to 400 amps continuously at 18 to 40 volts. The 8830 can only supply 350 amps.

The rectifier has optional running gear to make it portable within the shop. You have the option to remotely locate the wire control feed box from the rectifier.

We have a versatile spray pattern.

The at 400 comes is available with three air caps, the high velocity, the open, and the fan air caps. The high velocity is versatile in design that if a focused high pressure spray pattern is needed, you just increase the air pressure. The 8830 has to offer a "AirJet" option to make up for it's limit on the spray pattern with its standard air cap. Additionally, you can get a fan air cap for the AT 400 that allows a wider pattern for the larger surface area jobs. Again, no tools required to vary the spray pattern.  The open aircap allows you to be able to spray a very rough texture coating for traction, gripping, and anti skid applicaitons.

Approved Distributor for Thermach

Thermal Spray Depot is an approved distributor for Thermach.  At one time, there was a group called the Miller Thermal Group. That original division of Miller was sold and eventually moved to another state.  The original design and production teams from Miller stayed in Wisconsin to become the independently owned Thermach. Praxiar Tafa is a regestered trademark of Praxair.  The tafa 8830 and the BP 400 are registered trademarks of Praxair.