Metallisation launches new ARC150 system

Anti-Corrosion Methods and Materials

ISSN: 0003-5599

Article publication date: 5 January 2015



(2015), "Metallisation launches new ARC150 system", Anti-Corrosion Methods and Materials, Vol. 62 No. 1.



Emerald Group Publishing Limited

Metallisation launches new ARC150 system

Article Type: New materials and equipment From: Anti-Corrosion Methods and Materials, Volume 62, Issue 1

Metallisation has launched its new ARC150/S500-CL arcspray system, which has been specifically designed for higher throughput with up to 500 A capacity.

The new ARC150 has been developed over a long period of time, building upon the proven technology of the highly successful Metallisation arcspray systems. Metallisation is committed to the continual development of its systems to maximise spraying capacity, coating quality, system performance/reliability and customer experience. The new ARC150 has been developed as a direct response to customer requests for a flexible system, with higher throughput, than the current Metallisation 350 A arcspray systems. Customers also suggested that, in some situations, the 600 A and 700 A systems can be heavy and difficult to manoeuvre because of the required cable capacity.

There are many benefits of the new ARC150 system. It retains the long supplies pack options and flexibility, offered by the current ARC140 system, and has an increased throughput of around 40 per cent compared to traditional Metallisation 350 A systems. The pistol, energiser, drive system and supplies pack have all been redesigned to support the increased capacity.

The ARC150 pistol has improved airflow, which delivers a finer coating and optimised reliability at the higher spraying current. The pistol has easily changeable V-rollers for positive wire feed and increased capacity of its contact tubes, all designed to suit the increased current, while maintaining the proven, low maintenance design of its arcspray pistols. The contact tube arrangement is also a new design, which utilises tubes with larger contact areas and replaceable contact tips. The tips are made from a specialist, hard-wearing material, which aids the dissipation of heat build-up. It takes less than 5 minutes to change the contact tubes and air concentrator, which do not require adjustment once installed, saving further operator time.

The new S500-CL energiser features sealed electronics for reliable operation in the harshest of spray environments. All new digital gauges offer both scale and numeric displays with high contrast, which are easily visible in light or dark conditions or through shaded visors. The new energiser benefits from closed-loop current control, enabling the operator to set the spray current before spraying commences. It also protects the system from spraying at currents higher than 500 A. Metallisation specifically chose 500 A, as opposed to 700 A, as a manageable production rate to provide a balance between high throughput, system weight and high-quality coatings. The energiser is PLC controlled by an industrial PLC unit, dramatically reducing the electrical components and increasing reliability.

The push/pull drive system is based on the Metallisation patented “Synchrodrive” system and has a new, higher capacity sealed motor and flexible drive arrangement, which allows wire feed up to a length of 20 m. The new ARC150 provides a long reach with lightweight flexibility of the pistol and supplies, which delivers comfortable and productive working conditions for the operator.

The new ARC150 system is ideal for traditional, high throughput corrosion protection applications spraying 2.3/2.5 mm zinc, aluminium and alloys such as ZnAl 85/15. The 500 A spraying capacity increases productivity for large areas, by over 40 per cent compared to 350 A systems, while retaining its flexibility when spraying smaller or more complex areas.

The varying length supplies pack all have air cooled cables for the last 2.5 m leading to the pistol, which reduces the pistol weight and lessens operator fatigue. The design of the new energiser allows for multiple customer-specific packaging options for the wire and drive dispense. Overall, the new system has low running costs when compared with gas systems and is easy to maintain. Typical performance figures for the ARC150 can be seen in the Table I below.

Table I Typical performance figures for the ARC150 pistol

Throughput is assumed to be independent of wire diameter. All data are an approximation and is offered as guidance only, as performance can vary depending on application and parameters.

There is a growing industry requirement for high temperature alloys to be metal sprayed, such as Inconel 625 or Hastelloy C276, which can be applied using the ARC150 system. To enable applicators to use the ARC150 for these applications, a 1.6-mm conversion kit is available from Metallisation (Figure 2).

Figure 2 ARC150 arcspray system from Metallisation

Stuart Milton, Sales Director, Metallisation says:

We are really proud of the new ARC150. All of our arcspray systems have a proven track record and continually deliver excellent anti-corrosion and engineering coatings, however, we are always keen to develop and enhance our equipment and processes to benefit our customers. The ARC150 energiser has been produced under our new lean manufacturing process. This is helping us to respond to our customers with shorter lead times, deliver standardisation of our products and enhance the excellent customer service we provide.

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