Another disadvantage of wire-arc spraying is the lack of control over the size of the
produced particles. In most thermal spray processes, the molten droplet sizes are determined by
solid particle sizes in the fed powder, whereas, the molten droplet sizes in wire-arc are
determined by the operating parameters. It should be noted that particle size controls dynamic
and thermal behavior within the spray and the splashing and spreading behavior during
deposition. Therefore, lack of control over particle size effectively limits the ability to adjust
coating characteristics according to wide range of industrial requirements, thereby narrowing the
range of wire-arc applications.