The Arc Spray Process utilizes a pair of electrically conductive wires, which are melted by means of an electric arc. The molten material is then atomized by compressed air and propelled onto a substrate surface. The impacting molten particles rapidly solidify on the substrate to form a coating.

This process is referred to as cold process (relative to the substrate material being coated) as the substrate temperature can be kept low during processing avoiding damage, metallurgical changes and distortion to the substrate material.