Thermal Spray, Hardfacing & Wear Coatings worked example

Wire Consumption at 98% deposit efficiency: a worked example

What does the result look like when deposit efficiency reaches 98%? The full calculation is worked below with real intermediate numbers. Use it when wire consumption in thermal spray, hardfacing and wear coatings needs a buy quantity for the next thermal spray, hardfacing and wear coatings run and you do not want to short the line.

The inputs for this scenario

  • Total surface area to coat: 500 units (unchanged)
  • Wire needed per unit area (as-deposited): 0.08 units (unchanged)
  • Deposit (transfer) efficiency: 98 % (raised for this scenario; the documented default is 85)

Working through the calculation

  • Applying the documented formula (Required wire consumption = covered amount × use per unit ÷ transfer efficiency) to the inputs above produces each figure below.
  • At this operating point the engine returns 40.82 units for required quantity, the number this scenario is built around.
  • At this operating point the engine returns 40 units for theoretical amount.
  • At this operating point the engine returns 0.82 units for loss allowance.
  • At this operating point the engine returns 98 % for efficiency.

How this compares with the baseline

  • Against the tool's baseline example, where deposit efficiency sits at 85% and the headline result is 47.06 units, this scenario comes in 13.27% below the baseline at 40.82 units.
  • A figure at this level is achievable when deposit efficiency is genuinely sustained, not just peaked for a shift. Transfer efficiency for wire processes shifts with atomizing air pressure, arc current, and spray distance, so a single stored figure will not fit every part; verify against your own arc-spray logs.

Results at a glance

  • Required quantity: 40.82 units (headline result)
  • Theoretical amount: 40 units
  • Loss allowance: 0.82 units
  • Efficiency: 98 %

Run it with your numbers

  • Every input above is editable in the live Wire Consumption calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.