Abstract: A microprocessor controlled arc metalizing unit includes a wire cassette and a drive mechanism cassette engaged in a separable manner. By disengaging the wire cassette and drive mechanism cassette, an operator has much greater control of the unit since the wire loaded wire cassette is fixed and the operator need only maneuver the lightweight drive mechanism cassette. To improve the safety of the arc metalizing unit, a “dead-man” switch acts to automatically shut down the arc metalizing unit should any number of preestablished safety conditions be breached. In addition, one or more composite housings enclose the operational components of the arc metalizing unit to improve safety. Reliability is improved through a tension control unit that eliminates any rotational fluctuations associated with wire spools. The arc metalizing unit further incorporates a touch pad control with a display for operating the unit and displaying the status of the unit.