Australia Surface Treatments

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VISY
Alcoa
Nestlé
Fonterra
Saputo
ARYZTA
George Weston Foods
Allied Pinnacle
Laurent
Mackies Bakeware
American Pan
KAAK
KEMPF
SASA
Latrobe Magnesium
Goodman Fielder
Pfizer
Rio Tinto
Defence Department
Coating Technologies

Metal Spray Coating Services

AST provides wire arc spray metal coating services using chrome, stainless steel and nickel wire. The twin wire arc spray process builds dense, wear-resistant metal coatings on industrial components for dimensional restoration, corrosion protection, hard chrome replacement and surface engineering.

Wire arc spray is an environmentally safer alternative to hard chrome plating — no hexavalent chromium, no hazardous plating baths.

Last updated: April 2026

Wire arc spray is a thermal spray process — distinct from AST's fluoropolymer and graphite-resin coating services. Where fluoropolymers provide non-stick, chemical resistance and barrier protection, metal spray coatings provide hardness, wear resistance, corrosion protection and the ability to restore worn components to original dimensions. AST offers three primary wire materials, each selected to match the service environment.

Chrome

Chrome Wire Spray

Hard chrome replacement coating achieving hardness comparable to electroplated chrome. Can be ground and polished to mirror finish for hydraulic rods, cylinder bores and sealing surfaces. Eliminates the environmental hazards of hexavalent chromium plating baths while matching or exceeding plated chrome performance. No micro-cracking — unlike electroplated chrome which develops fine crack networks that create corrosion pathways.

  • Hard chrome plating replacement
  • Hydraulic rods and cylinder bores
  • Sealing and bearing surfaces
  • Ground and polished to mirror finish
Stainless Steel

Stainless Steel Wire Spray

304 and 316 grade stainless steel coatings for corrosion resistance, dimensional restoration and general engineering rebuild. 316 stainless provides excellent chloride and marine resistance. Good machinability after spraying, making it suitable for precision components that need to be returned to OEM specifications.

  • Corrosion resistance (marine, chemical, atmospheric)
  • Food-grade and dairy equipment
  • Pump shafts, impellers and sleeves
  • General engineering dimensional restoration
Nickel

Nickel Wire Spray

Pure nickel and nickel-chromium alloy coatings for high-temperature service, caustic and marine environments, and bond coat applications. Excellent corrosion resistance in seawater, alkali and chemical process environments. Used where operating temperatures or chemical exposure exceed the capability of stainless steel coatings.

  • High-temperature oxidation resistance
  • Caustic and marine corrosion protection
  • Boiler tubes and heat exchangers
  • Bond coats for multi-layer systems
Why AST

Why Choose AST for Metal Spray?

AST combines wire arc spray metal coating with fluoropolymer and graphite-resin coating under one roof. This means customers dealing with complex surface engineering problems have access to multiple coating technologies from a single applicator — rather than coordinating between separate specialists for different surface treatments.

  • Chrome, stainless steel and nickel wire spray
  • Combined with fluoropolymer and Resigraph capability
  • Machining and grinding to finished dimensions
  • Lifetime workmanship warranty

AST provides wire arc spray metal coating from our Melbourne facility, servicing customers across Australia. Combined with our fluoropolymer and Resigraph capabilities, AST offers a broader surface treatment service than single-technology applicators — backed by a lifetime warranty on workmanship.

Frequently Asked Questions

How does wire arc spray work?
Twin wire arc spray feeds two metal wires into a spray gun where an electric arc melts the wire tips at extreme temperatures. Compressed air atomises the molten metal into fine particles and accelerates them onto the prepared substrate. Particles flatten and mechanically interlock with the blasted surface, forming a dense lamellar coating layer by layer.
What is the bond strength of wire arc spray coatings?
Wire arc spray coatings typically achieve bond strengths of 30-70 MPa, depending on the substrate material, surface preparation quality and spray parameters. Proper surface preparation with an angular blast profile is the single biggest factor in achieving maximum bond strength.
Can wire arc spray coatings be machined after application?
Yes. Wire arc spray coatings in chrome, stainless steel and nickel can all be machined, ground or polished to finished dimensions and surface finish requirements after spraying. This is a key advantage for dimensional restoration work where components need to be returned to OEM specifications.
Is wire arc spray environmentally safer than hard chrome plating?
Yes. Wire arc spray eliminates the use of hexavalent chromium plating baths, which pose significant environmental and health hazards. The process uses only metal wire and compressed air, with no hazardous chemical baths to manage or dispose of. This makes it an increasingly preferred alternative as environmental regulations tighten.
What surface preparation is required for wire arc spray?
Components are abrasive blasted to create a clean, angular surface profile for mechanical interlocking. AST uses silica and glass bead blasting to prepare substrates before spraying. The prepared surface must be sprayed promptly to prevent oxidation that would compromise bond strength.

Only licensed industrial fluoropolymer applicator in Australia, New Zealand and South East Asia

Yearly technical and quality audits by Chemours Global

Lifetime warranty on workmanship

Need metal spray coating for your components?

Talk to AST about your dimensional restoration, wear protection or hard chrome replacement requirements. Our team can review your application and prepare a technical quotation.

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