Abstract
The paper investigates the influence of electric arc spraying process parameters using copper-plated Sv08G2S wire on the structure and performance characteristics of coatings formed on grade 45 steel. Spraying was performed at varying voltages and wire feed speeds, followed by a comprehensive analysis of the structure and properties of the resulting coatings. The best coating characteristics were achieved at 40 V, 280 A and a wire feed speed of 100 mm/s: the resulting coating exhibited a relatively dense and uniform structure, high microhardness (277.6 HV), minimal mass loss due to abrasive wear (0.018 g), and enhanced corrosion resistance. Electrochemical tests in a 3.5 wt.% NaCl solution revealed a positive shift of the corrosion potential to −0.318 V (vs. Ag/AgCl) and a low corrosion current density of 4.61 × 10⁻⁵ A/cm², corresponding to a corrosion rate of 0.54 mm/year. It is shown that voltage is one of the key parameters in supersonic arc metallization, governing arc stability, spray uniformity, and coating quality, whereas increasing the current and wire feed speed resulted in a thicker sprayed layer but promoted pore formation and reduced structural homogeneity. Overall, optimization of spraying parameters enables the formation of high-quality coatings with improved wear and corrosion resistance, thereby increasing the service life of steel components in practical applications.