Plasma Group Science

Thermal Spray Coating

 

Thermal Spraying Application Illustrations

Plasma Coating Process

High Velocity Oxy-Fuel Process

Flame Spray Process

Flame Spray Wire Process

Plastallium 212

 

Flame Spray Wire Process


Introduction

Wire spraying is used to apply a number of different metals and their alloys.

Main Applications

Commonly used in the build up of mis-machined parts, for applying corrosion resistant coatings to steelwork and as a bearing material

Process Description

A wire spray gun uses oxygen and acetylene to produce a flame through which metal wire is passed. The resultant molten metal is atomised by compressed gas and sprayed on to the prepared surface to form the coating.

General Coating Characteristics

    • bond strengths (20 - 30 mOa / 3000 - 4000 p.s.i.). 
    • macrohardness values between Rc 30 - 40 for some steel alloys. 
    • higher porosity levels than equivalent plasma sprayed coatings.

Available Coatings

In many cases wire spraying is a lower cost alternative to the plasma spray process for applying metals and is generally capable of building up thicker coatings than plasma. However, the range of available materials that can be sprayed is much lower than that for plasma. The table overleaf is a guide to the range of metals available, their properties and typical applications

Coating Characteristics Typical Applications

Copper/silicon Carbide (HIPAC)

Ask for the separate Data Sheet for more details

High thermal conductivity, five times greater than cast iron.
Good electrical conductivity.
High wear resistance
High energy absorbance and heat dissipation		 Used on components subjected to high friction wear and heat build up cauded by rotating machine parts. Major uses are for brake and clutch components particularly on racing cars, bikes and other forms of transport.
13% Chrome Steel

Macrohardness - Rc 33

Tensile bond strength - 28 Mpa (4000 p.s.i.)

High Strength

Used extensively as a build up material. It can be ground finished to tight tolerances to reclaim shafts, hydraulic rams, pistons, bearings, plungers and other general engineering components.
Aluminium

Macrohardness - RH 80
Tensile bond strength - 10 Mpa (1450 p.s.i.)
High resistance to corrsion:-

  • atmospheric
  • heat
  • chemical
With appropriate sealing of the coating aluminium can be used as an all purpose coating to prevent atmospheric corrosion and sea water attack on steel structures.
Aluminium Bronze Macrohardness - RB 80
Wear resistant.
Machines to excellent finish.		 It can be used for repairing defects in bronze castings.
Also for build up of worn areas on bushings, bearings and other bronze or brass items.

There are a number of other wires available. These are detailed below with possible applications. 
Coating Typical Applications
Tin/Antimony/Copper (Babbit) For heavy duty bearings
Zinc For general corrosion resistance for similiar applications to aluminium
Molybdenum For high wear areas such as wire capstans, brake drums and macine knives.

 

 

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Plasma Coatings Limited

Unit 3, Whitecross Road Industrial Park

Tideswell, North Derbyshire

SK17 8PY, England

e-mail : info@plasma-group.co.uk

Tel : +44 (0) 1298 873700, Fax : +44 (0) 1298 873708

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