By introducing electric arc spraying as an alternative for plasma spraying in 1993, the Engine Overhaul shop of KLM managed to transfer 90% of all metallic coatings from plasma into electric arc. This change was a big money safer.

Also the advantages of easy handling, forgiving process, high deposition efficiency and excellent coatings caused this process to be a big success for operators and management. Since 1993 KLM has been the most successful initiator of approvals and General Electric manual changes for new electric arc spray wires like Ni-Al, Al, Ni-Cr-Al, Inconel 718, Cu-Zn-Ag, Cu-Ni-In, Moly and Al-bronze. KLM bought 2 extra units in the late 90’s. KLM asked Praxair-Tafa in 1999 for a new sophisticated electric arc spray system for the aircraft industry with all kind of new features. This resulted in 2005 in the newest closed loop electric arc spray unit called the 9935. This paper will show KLM’s newest electric arc spray unit plus its unique features and will show the latest results on coatings sprayed by this unit.