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Combustion Wire Thermal Spray Process

Schematic Diagram of The Combustion Wire Thermal Spray Process
(also known previously as Flame Spray, Metallizing, and Metal Spray Processes)

A Complete Combustion Wire Thermal Spray (Flame Spray) Process Installation

The Combustion Wire Thermal Spray Process formerly known as Metallizing, Flame Spray and Metal Spray Processes was first invented in 1910 by Schoop in Switzerland. The flame spray process is basically 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 atomized 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. This flame spray process carried out correctly is called a “cold process” (relative to the substrate material being coated) as the substrate temperature can be kept low during processing avoiding damage, metallurgical changes and distortion to the substrate material. This flame spray process has been extensively used in the past and today for machine element work and anti-corrosion coatings. Ceramics and cermets can be used in rod or composite wire form.

                                                      Metco 10 E

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, synchromesh 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

Metal Spray Coating Photomicrographs



Combustion Wire Sprayed 13Cr Steel Coating

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