In Twin Wire Arc Spray two consumable wire electrodes are fed into a gun where they are electrically charged, creating an arc between the two wires. The heat from the arc melts the wire, then compressed gas or air propels fine droplets of molten metal to the surface of the part that is being coated.  The deposited metal creates a mechanical bond with the part.

The process is energy-efficient; it only requires about one-eighth the energy of other spray methods to melt the metal. This allows operating at lower temperatures. It has faster spray rates and higher deposition rates than other thermal spray processes as well, making arc spray one of the most efficient and cost-effective spray processes.