Apparatus and system for thermal spray and related methods thereof

A spray apparatus comprising:

• a housing;
• a first electrode and a second electrode disposed in the housing, wherein the second electrode is spaced apart from the first electrode;
• a first contact tip removably attached to the first electrode and a second contact tip removably attached to the second electrode, wherein at least one of the first contact tip or the second contact tip comprises a disc comprising a first end and a second end, wherein the first end comprises a front face and the second end comprises an opposing rear face, wherein the disc comprises a plurality of grooves disposed radially around the disc extending from the rear face to the front face to provide rotationally indexable wear surfaces;
• and
• a nozzle between the first contact tip and the second contact tip, wherein the first contact tip and the second contact tip are configured to deflect and guide the wire towards the nozzle prior to atomization;
• a first wire that is configured to be inserted through the housing to be deflected and guided by one of the plurality of grooves of the first contact tip to the nozzle, wherein the one of the plurality of grooves is in plane with the first wire;
• and
• a second wire that is configured to be inserted through the housing to be deflected and guided by one of the plurality of grooves the second contact tip to the nozzle, wherein the one of the plurality of grooves is in plane with the first wire, wherein the first wire and second wire intersect at the nozzle for atomization of the first wire and second wire;
• wherein the first contact tip and the second contact tip comprise an adjustment mechanism disposed on an exterior of the housing;
• wherein the position of the first contact tip or the second tip is configured to be adjusted via the adjustment mechanism to provide one groove of the plurality of grooves in plane with first wire or the second wire without disassembly of the housing.