Spray welding, also known as flame spraying, is a versatile welding process used in various applications. In this guide, we will cover the basics of spray welding, compare it to other popular welding methods like MIG and TIG welding, and explore the different techniques used in spray welding.

As a manufacturer specializing in custom designs and large-scale production of metal and wire products, we understand the importance of using the right welding technique for each sheet metal application.

Whether you work in purchasing, procurement, or logistics, this guide will help you choose the best welding technique. So, let’s read on!

What We’ll Cover:

MIG (Metal Inert Gas) Welding

MIG welding uses a wire-feeding gun that feeds a wire electrode through the welding gun and into the weld pool. This type of welding is fast, easy to learn, and compatible with various metals, including aluminum, stainless steel, and mild steel.

TIG (Tungsten Inert Gas) Welding

TIG welding uses a tungsten electrode to create the weld and a separate filler material to strengthen the weld joint. This type of welding is precise and produces high-quality welds. It is often used in industries where aesthetics and precision are important, such as medical wire, aerospace, and automotive.

Stick Welding

Stick welding (also known as Shielded Metal Arc Welding or SMAW) uses a consumable electrode coated in flux to create the weld. This type of welding is versatile, can be used on various metals and alloys, and is often used in construction and industrial applications.

Flux-Cored Arc Welding (FCAW)

FCAW is similar to MIG welding but uses a hollow electrode filled with flux to protect the weld from contamination. This type of welding is fast, easy to learn, and can be used on thick materials.

Plasma Arc Welding (PAW)

PAW uses a highly focused plasma arc to melt the metal and create the weld. This type of welding is precise, produces high-quality welds, and is often used in aerospace and high-tech industries.

These are just a few of the most common types of welding. Each type has its advantages and disadvantages. The best type of welding for a particular application will depend on factors such as the type of metal being welded, the thickness of the material, and the desired strength and appearance of the weld.

Integrating Tube Fabrication with Welding Techniques

Welding plays a pivotal role in tube fabrication, a critical process in creating complex assemblies used across various industries. Tube fabrication involves multiple steps, including tube bending, tube cutting, and finally, welding, to ensure structural integrity and functionality. By utilizing advanced welding techniques such as MIG, TIG, and particularly spray welding, manufacturers can achieve high precision and strong welds essential for tube assemblies.

Tube bending shapes the tubes into necessary configurations, which are then cut to precise lengths. The cut sections are welded together, often using commercial and professional welding practices that ensure durability and strength. Spray welding, in particular, offers a unique advantage due to its ability to apply protective coatings that enhance the longevity and performance of tube structures. This method is incredibly beneficial for industries that require robust tube formations, such as automotive exhausts, aerospace hydraulics, and architectural frameworks.

At Wirefab, our expertise extends beyond simple welding applications. With over 65 years of experience in the manufacturing sector, we leverage our knowledge to provide comprehensive services that include tube fabrication. By integrating sophisticated tube bending and cutting processes with our advanced welding capabilities, we deliver custom, high-quality solutions tailored to meet the diverse needs of our clients. Whether it’s creating intricate parts for medical devices or robust components for industrial machinery, Wirefab’s commitment to precision and excellence ensures optimal outcomes for all our clients’ manufacturing projects.

Looking for medical wire products? Learn more here!


How Does Spray Welding Affect Wire Forming?

Spray welding, also known as flame spraying, is a welding process that involves spraying molten metal or wire particles onto a surface to create a bond. In spray welding, a wire or powder feedstock is melted by a flame or plasma torch and sprayed onto a prepared surface, forming a coating or build-up layer. This process often repairs worn or damaged parts or applies a protective coating to a surface.

When it comes to wire formation, spray welding can significantly affect the wire’s properties. The high-velocity impact of the molten particles on the substrate can cause deformation and work-hardening of the wire, which can affect its tensile strength and other mechanical properties. Additionally, the heat generated during the spray welding process can cause the wire to undergo thermal stresses, further altering its properties.

To mitigate these effects, it’s important to carefully control the spray welding process, including the temperature of the torch and the velocity and angle of the spray particles. These specifications can help ensure that the wire retains its desired properties and is suitable for its intended use, i.e., baskets in material handling.

What Are the Advantages of Spray Welding?

Spray welding offers several compelling benefits that make it a preferred choice for diverse manufacturing needs. It is notably cost-effective, minimizing both equipment and operational expenses, making it ideal for large-scale applications. The process is renowned for its high deposition rates, which allow for the quick application of thick material layers, enhancing efficiency. Moreover, spray welding produces exceptionally strong metallurgical bonds, ensuring the durability and longevity of the welds. Additionally, the low heat input characteristic of spray welding helps in reducing substrate distortion, preserving the integrity and precision of the components being welded.


Spray welding is often more cost-effective than other processes, particularly large-scale production runs. It also requires less equipment and setup time, further reducing costs.

High Deposition Rates

Spray welding has high deposition rates, meaning it can apply a thick material layer in a single pass. This seamless design makes it an efficient process for coating or repairing large surfaces.

Excellent Bonding

Do you need strong bonds and seams? Spray welding creates a metallurgical bond between the sprayed particles and the substrate. This benefit produces a strong, durable bond that can withstand harsh environments and high stresses.

Minimal Distortion

Because spray welding involves low heat input, it can minimize distortion and warping of the substrate, which is particularly important for precision applications.

Key Takeaways

In conclusion, spray welding is an exciting and innovative process that offers many advantages over other types of welding. It is a versatile and cost-effective technique to repair, protect, and coat various materials. As a result, spray welding is a powerful tool for manufacturers in various industries.

Wirefab, a leading custom wire fabricator in the U.S., is proud to offer spray welding services to help other manufacturers fulfill their custom designs and large-scale wire production needs. Using spray welding, Wirefab can create strong, durable bonds that can withstand harsh environments and high stresses while minimizing distortion and warping of the substrate.

If you’re looking for a reliable and experienced partner to help with your welding needs, contact Wirefab today! Our team of experts can help you develop a customized solution that meets your requirements. Whether you need to repair worn parts or apply a protective coating to a surface, we’ve got you covered.

Don’t settle for subpar welding services. Choose Wirefab and experience the benefits of spray welding for yourself. Contact us today to learn more and start your project!

We have 300+ machines to meet your manufacturing quota.



Above all, we’re here to be your greatest resource in contract manufacturing. We conduct all of our stainless steel wire fabrication in the heart of New England. Plus, we’re ready to ship anywhere in the U.S.!

Wirefab Inc. has over 65 years of experience in custom sheet metal fabrication as one of New England’s top custom welding service companies. Whether you need custom CNC machininglaser metal cutting, or material handling cartswe’re here to help. Above all, we’re always eager to solve our customers’ problems with a broad range of custom wire fabrication services. Contact us today to see how we can simplify your next project.

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