Flame Wire Spraying

The extrudable materials for this process are metals and alloys that can be drawn into a wire shape, and have a melting point that is far below the temperature of the heat source used.

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Benefits

Micro porous lamellar structure
Relatively high degree of oxidation in the coating
Moderate tensile strength
Good compressive strength
Low elongation properties
Economic thermal spraying process
Transportable process, coating on location possible

Applications

Piston rings with molybdenum for improved wear resistance and running properties (coefficient of friction)
Corrosion protection for locks, bridges, etc. with aluminium, zinc and their alloys
Repairs or dimension corrections of worn drive shafts or bearing seatings with stainless steel alloys
Sleeve bearing surfaces with white metal (Babbitt) or bronze
Electrical shielding with tin, zinc, etc.

Overview

Autogenous wire spraying or wire flame spraying is the oldest process in thermal spray technology. Using an electric or air motor a material is transported as a wire through a spray gun and melted down centrally in a burning gas-oxygen mixture (usually acetylene-oxygen). Subsequently, compressed air is used to spray the molten material onto the substrate to form a coating.

The extrudable materials for this process are metals and alloys that can be drawn into a wire shape, and have a melting point that is far below the temperature of the heat source used. If zinc, aluminium, or a zinc-aluminium alloy is used for the wires, it is also called metal spraying.

Process properties

Material Form: Wire (sometimes cord or rod shape)

Thermal energy source: by combustion of a fuel and oxygen

Process fuel: propane, hydrogen, acetylene

Process temperature: < 4,000ºC

Spray particle speed: < 150 m/s

Typical coatings

Various stainless steel alloys
Nickel-based alloys
Molybdenum
Aluminium
Copper and copper alloys
Zinc, Tin, etc.