Abstract
In this review article, modern approaches to improving the performance characteristics of coatings produced by electric arc spraying are analyzed. Particular attention is given to studies in the field of directed energy deposition using an electric arc (DED-Arc), including the selection of spraying parameters, substrate surface preparation, and the application of new types of wires and composite materials. Advances in feedstock design for corrosion-resistant, heat-resistant, and wear-resistant protection are reviewed, including Zn, Al-Mg, and Zn-Al-Mg systems, Al-Cu cored wires for antifouling applications, stainless steel and NiCrMoAl alloys, cermets, and WC-reinforced high-entropy alloys. The review also summarizes recent results on adhesion enhancement through laser surface texturing and on adapting electric arc spraying technology for non-conductive substrates. Particular attention is given to the relationships between processing parameters, coating microstructure, and functional properties. The analysis highlights key factors controlling coating performance and identifies current research challenges in arc-sprayed coating systems. The summarized results demonstrate that electric arc spraying is a flexible and cost-effective technology for producing functional coatings with tailored properties for a wide range of industrial applications.