Abstract
This study investigates the effect of wire feed rate on the structure and properties of coatings produced by electric arc metallization using 30KhGSA wire. The coatings were deposited onto 65G steel substrates at feed rates of 5, 7, and 9 cm/s using supersonic arc spraying. A comprehensive characterization was performed, including microstructural analysis, EDS mapping, X-ray diffraction, and evaluation of coating thickness, hardness, and porosity. The results indicate that an increase in wire feed rate leads to greater coating thickness but reduces structural homogeneity. At 5 cm/s, the coating exhibited a uniform microstructure and low porosity, though with limited thickness. The intermediate feed rate of 7 cm/s provided optimal properties, including balanced thickness (up to 220 µm), reduced porosity (4.3%), and high hardness (up to 720 HV). At 9 cm/s, further thickness growth was accompanied by turbulent deposition, resulting in increased porosity and structural defects. These results confirm that wire feed rate is a decisive factor in coating quality, and its optimization is essential for achieving durable and reliable protective layers.