Wire Flame Spray
The Combustion Wire Thermal Spray Process is the spraying of molten metal onto a surface to provide a coating. Material in wire form is melted in a flame (oxy-acetylene flame most common) and atomised using compressed air to form a fine spray. When the spray contacts the prepared surface of a substrate material, the fine molten droplets rapidly solidify forming a coating.
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, syncro 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
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, syncro 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

Metal Coat - Wire Flame Spray Equipment Manufacturer
Metal Coat has applied its engineering excellence and vast knowledge of thermal spray technology to develop a complete line of wire flame spray guns for thermal spray applications. We have been manufacturing thermal spray equipment and coating systems for over 30 years now, and hence we are undoubtedly experts at thermal spray equipment manufacturing. Our product range of wire flame spray equipment comprises of air turbine-driven models – 11M, 12M, and 14M Wire Flame Spray Equipment; and electric motor driven models – 5KM, 11ED, and 12ED Wire Flame Spray Equipment. Our wire flame spray systems are designed for both manual and automatic applications. Although Wire Flame spray systems are operated manually for most of the applications, if required, it is possible to semi-automate or completely automate our systems. We also keep a big stock of our thermal spray spare parts for the immediate needs of our customers. Please see below our wire flame spray equipment range for more details. You can find the brochures of all the models on the product page.
Wire Flame Spray Equipment
Metal Coat provides a wide variety of wire flame spray equipment that supports our clients’ diverse needs. Our 11M, 12M, and 14M Wire Flame Spray torches are air turbine-driven, whereas 5KM, 11ED, and 12ED are electric motor driven. Our 11M Wire Flame Spray is designed to spray soft and low melting wires efficiently, whereas 12M and 14M can be used to spray both soft and hard wires. The only difference between the two is that in 12M wire flame spray equipment, the wire drive is regulated through a cam lever, whereas in 14M Wire Flame Spray equipment it is thumb fed hence making the start/stop operation easier. Our 5KM Wire Flame spray system is specially designed for robust and high-volume production in an automated environment. 11ED Wire Flame gun is designed to spray low melting point soft wires. The wire feed is monitored using a DC powered motor. Our 12ED Wire Flame Spray gun can be used to spray high melting point, hard wires. It is operated by an AC powered motor. All our electric drive models have a significantly a smaller number of components that the air turbine powered models, thereby facilitating easy usage, with less downtime. Our wire flame spray equipment typically uses acetylene as fuel gas. Where acetylene is not available, our propane systems can be used for wire flame spray coatings.
Our Wire Flame Spray Systems

Our Wire Flame Spray Systems
Suitable for high volume production in an automated environment
The Metal Coat 5KM Wire Combustion Gun is driven by a powerful constant-speed motor that provides precise control of wire speed and is ideally suited for automated high-volume production spraying.
This wire flame spray gun has constant motor control over a wide range for uniform wire feed.
This system is very durable with stable operation.
The 5KM Wire Flame Spray operates reliably and economically, with minimal downtime.
When a heavy-duty gun is required for high-volume or continuous combustion wire flame spray production, the Metal Coat 5KM gun provides excellent performance.

11M Wire Flame Spray Gun
Suitable for high volume production in an automated environment
The Metal Coat 5KM Wire Combustion Gun is driven by a powerful constant-speed motor that provides precise control of wire speed and is ideally suited for automated high-volume production spraying.
This wire flame spray gun has constant motor control over a wide range for uniform wire feed.
This system is very durable with stable operation.
The 5KM Wire Flame Spray operates reliably and economically, with minimal downtime.
When a heavy-duty gun is required for high-volume or continuous combustion wire flame spray production, the Metal Coat 5KM gun provides excellent performance.

12M Wire Flame Spray Gun
Suitable for high volume production in an automated environment
The Metal Coat 5KM Wire Combustion Gun is driven by a powerful constant-speed motor that provides precise control of wire speed and is ideally suited for automated high-volume production spraying.
This wire flame spray gun has constant motor control over a wide range for uniform wire feed.
This system is very durable with stable operation.
The 5KM Wire Flame Spray operates reliably and economically, with minimal downtime.
When a heavy-duty gun is required for high-volume or continuous combustion wire flame spray production, the Metal Coat 5KM gun provides excellent performance.

14M Wire Flame Spray Gun
Suitable for high volume production in an automated environment
The Metal Coat 5KM Wire Combustion Gun is driven by a powerful constant-speed motor that provides precise control of wire speed and is ideally suited for automated high-volume production spraying.
This wire flame spray gun has constant motor control over a wide range for uniform wire feed.
This system is very durable with stable operation.
The 5KM Wire Flame Spray operates reliably and economically, with minimal downtime.
When a heavy-duty gun is required for high-volume or continuous combustion wire flame spray production, the Metal Coat 5KM gun provides excellent performance.

11ED Electric Drive Wire Flame Spray Gun
Suitable for high volume production in an automated environment
The Metal Coat 5KM Wire Combustion Gun is driven by a powerful constant-speed motor that provides precise control of wire speed and is ideally suited for automated high-volume production spraying.
This wire flame spray gun has constant motor control over a wide range for uniform wire feed.
This system is very durable with stable operation.
The 5KM Wire Flame Spray operates reliably and economically, with minimal downtime.
When a heavy-duty gun is required for high-volume or continuous combustion wire flame spray production, the Metal Coat 5KM gun provides excellent performance.

12ED Electric Drive Wire Flame Spray Gun
Suitable for high volume production in an automated environment
The Metal Coat 5KM Wire Combustion Gun is driven by a powerful constant-speed motor that provides precise control of wire speed and is ideally suited for automated high-volume production spraying.
This wire flame spray gun has constant motor control over a wide range for uniform wire feed.
This system is very durable with stable operation.
The 5KM Wire Flame Spray operates reliably and economically, with minimal downtime.
When a heavy-duty gun is required for high-volume or continuous combustion wire flame spray production, the Metal Coat 5KM gun provides excellent performance.