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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
Industries

Metal Spray Coating Services

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

Components can be coated, machined and returned to OEM specifications — often faster and more cost-effectively than replacement.

Last updated: April 2026
Wire arc spray metal coating process in industrial workshop

Dimensional Restoration

Wire arc spray rebuilds worn shafts, journals, bearing housings, rolls and cylinders back to original dimensions. The process deposits metal at high rates, building coatings from 0.1 mm to over 6 mm thick. After spraying, components are machined or ground to finished dimensions and tolerances — restoring valuable equipment at a fraction of replacement cost.

  • Worn shaft and journal rebuilding
  • Bearing housing restoration
  • Cylinder bore repair
  • Roll and roller resurfacing

Wear & Corrosion Protection

Metal spray coatings provide hard, dense surfaces that resist abrasion, erosion, sliding wear and corrosion. Chrome wire spray achieves hardness comparable to hard chrome plate — without the environmental hazards of hexavalent chromium plating baths. Stainless steel coatings provide corrosion resistance in marine, chemical and food-grade environments. Nickel coatings suit high-temperature and caustic service.

  • Hard chrome replacement (no hexavalent chromium)
  • Marine and chemical corrosion resistance
  • Abrasion and erosion protection
  • High-temperature oxidation resistance

Materials Available

AST offers wire arc spray in three primary material families, each selected based on the service environment and performance requirements of the component.

Chrome

Hard chrome replacement, wear resistance, ground and polished finish for hydraulic rods, cylinder bores and sealing surfaces.

Stainless Steel (304 / 316)

Corrosion resistance, food-grade applications, general engineering rebuild. 316 grade for chloride and marine environments.

Nickel

High-temperature service, caustic and marine environments, bond coats for multi-layer systems.

Metal spray coating technology →

AST's metal spray capability complements our fluoropolymer coating services, giving customers access to both surface technologies from a single applicator. Whether the requirement is a wear-resistant chrome spray on a hydraulic rod or a PTFE non-stick finish on a food processing line, AST has the capability and experience — backed by a lifetime workmanship warranty.

Frequently Asked Questions

What is wire arc spray coating?
Wire arc spray (also called twin wire arc spray) is a thermal spray process that melts metal wire using an electric arc and propels the molten metal onto a prepared substrate using compressed air. It produces dense, mechanically-bonded metal coatings for wear protection, corrosion resistance and dimensional restoration. AST offers wire arc spray in chrome, stainless steel and nickel.
What metals can be applied by wire arc spray?
AST sprays chrome wire (for hard chrome replacement and wear resistance), stainless steel wire (304 and 316 grades for corrosion resistance and general engineering), and nickel wire (for high-temperature, caustic and marine applications). Each material is selected based on the service environment and performance requirements of the component.
Can wire arc spray replace hard chrome plating?
Yes. Chrome wire arc spray coatings achieve hardness comparable to hard chrome plate and can be ground to a mirror finish for hydraulic rods, cylinder bores and sealing surfaces. Wire arc spray avoids the environmental and health hazards of hexavalent chromium plating baths, can build significantly thicker coatings, and eliminates the micro-cracking typical of electroplated chrome.
How thick can wire arc spray coatings be applied?
Wire arc spray coatings typically range from 0.1 mm to over 6 mm, depending on the application. Common engineering builds are 0.4-1.0 mm for wear and corrosion protection. Thicker builds are used for dimensional restoration where significant material has been lost through wear or corrosion.
What industries use metal spray coating?
Mining, oil and gas, marine, paper and pulp, power generation, general engineering, food and beverage, water treatment, and defence. Typical components include pump shafts, impellers, hydraulic cylinders, bearing journals, rolls, valve bodies and offshore structures. AST provides metal spray services from its Melbourne facility for customers across Australia.

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 a Quote for Your Equipment?

Talk to AST about your coating requirements, operating conditions and performance goals. Our team can review your application and prepare a technical quotation.

Request a Quote