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This process melts wire feedstock in a flame and atomizes it using compressed air to form fine droplets. The flame is fueled chemically (often acetylene with oxygen). Atomized molten material is propelled toward the substrate and solidifies rapidly to form a coating. Spray rates for stainless steel range from 0.5 to 9 kg/h (1 to 20 lb/h), with lower melting materials like zinc spraying at higher rates. Substrate temperatures are typically 95 to 205 °C due to flame energy input. Usually, under 10% of input energy melts the feedstock.

Characteristics of Wire Flame Spraying Process Coatings

  • The subjects to be sprayed are not affected by high temperature, which keeps the dimensional stability and morphological stability, causes no cracks, no strength reduction.
  • The coating with broad range of its thickness is available.
  • The coating contains harder particles than those of original materials and hard ingredients including metal oxide, nitride, carbide and etc., which provide high level of wearing resistance.

Common Materials Sprayed

  • Zinc and aluminium for anti-corrosion cathodic coatings on steel
  • Nickel/aluminium composite wire for bond coats and self-bonding coatings
  • Molybdenum for bond coats
  • Molybdenum for hard bearing applications, excellent resistance to adhesive wear, used on piston rings, synchro mesh cones and journals.
  • High Chromium steel for many applications requiring hard and wear resistant coating
  • Bronzes, Babbitt for bearing applications
  • Stainless Steels, Nickel and Monel for anti-corrosion and wear
  • Aluminium, nickel/aluminium for heat and oxidation resistance