Thermal Spray Technology
Auxiliary Equipments
Untitled Document
We understand that high quality spray equipment without compatible, quality Coating materials can lead to less than desirable coatings. Only wires designed and produced for thermal spraying ensures trouble-free application and superior, consistent coatings. Strict specifications and production controls guarantee that each wire is manufactured to a precise metallurgical composition and free from surface defects and contaminants. Care is taken to ensure that our wires have the proper physical properties for thermal spraying — tensile strength, hardness, and surface finish — and that they are properly packed/spooled for reliable performance.
Thermal Spray Wire
All type of metals, alloys, stainless steel, molybdenum wires available in coil, spool to suit both flame and arc spray process.
Stainless Spray I 18/8 types Chromium-Nickel, Austenite Machinable Rb 80-90 AISI 304 A general purpose stainless for corrosion protection. Resistant against sea water and slightly corrosive acids. Wear resistant also. Applications include pump shafts in ship building and fish processing industry, textile rolls.
Stainless Spray II Chrome alloyed. Grinding only Rc 42 - 48 AISI 420 Chromium steel for the application of hard layers, good wear resistance and emergency running characteristics. Substitute for hard chrome plating, fair corrosion-resistance, e.g. for plungers, hydraulic pistons, sliding surfaces, shafts and machine elements.
Stainless Spray III Chrom-Nickel-Moly- Austenite Steel. Machinable Rb 94 - 98, AISI 316 As stainless spray I, but with higher corrosion and wear resistance bright and shining finish.
Spray Steel 80 High carbon Steel, Grinding. Rc 42 - 48 A low shrink, high carbon steel wire developed for applying hard wear resistance coating, such as crankshafts, camshafts, etc.
Spay Steel 10 Low Carbon Steel, Machinable Rb 90 - 96 A general purpose carbon steel for rebuilding worn steel parts where excellent machinability is the main consideration. Fair wear resistance. Suitable for press fit mis-machined parts ball bearings seat etc.
Spray Steel 25 Mild Steel, Machinable Rc 30 - 35 This is a carbon steel similar to Spray Steel 10, except that it is harder and has a lower shrink factor. Machinability and wear characteristic are both good.
Molybdenum 99% Moly., Grinding, Rc 44 - 45 It is frequently used as a bond coat due to its very good bong strength between the surface of base metal and sprayed metal. Though molybdenum is a costly wire, the sprayed thickness required for excellent bonding is only 0.015". It is also used as a top coat material due to low friction characteristics and high particle hardness. General applications are syncro rings, piston rings, clutch parts etc.
Nickel - Aluminide Hardness 20 - 25 HRC A unique pre-alloyed wire of nickel & aluminium. Good resistance to high temperature oxidation and thermal shock. Excellent self bonding to many substrates. Used as bond coat also. Useful for brazing jigs, heating crucibles, casting ladles etc.
Aluminium - Bronze Bronze containing about 9% aluminium. Resistant against wear and corrosion through sea water, low shrinkage, used in ship building, engine and machine construction.
Tin - Bronze As above very good surface quality, limited corrosion resistance, e.g. for sea water main pumps, centrifugal pumps shafts.
Phos - Bronze A phosphor bronze for special repair of phosphor bronze items. Machines well.
Tin Based Babbitt Suitable for bearings, segment rings and bushes, can be subjected to high dynamic and static loads, extremely silent-running characteristics, also with tight fit, excellent emergency running characteristics.
Lead Based Babbitt To be used as explained above, but only structural parts of less precision and with higher dimensional tolerance.
Copper Hardness 37 - 40 Rb For coatings to serve as electrically conductive layers on non-conductive materials. For rolls and cylinders used in paper and textile industry.
Pure Nickel (99.9%) For high-quality surface protection.
Pure Tin (99.9%) For surface protection of food industry equipment.
Tin - Zinc For obtaining solderable and conductive surface on non-conductive substrate. Also suitable for preparation of moulds for low pressure injection moulding.
Zinc (99.9%)   For protection of iron and steel structures of all types and size against corrosion both in atmosphere and when immersed in either fresh or salt water. External coating on LPG cylinders, Capacitors, internal coating of tanks, bridges, dam sections etc. Better corrosion protection than pure zinc.
Zinc Aluminum (85/15)
Aluminium (99.5%) Corrosion protection against sea water, hot water and industrial atmospheres. Also for heat resistant for crucibles, firebox and doors & burner tubes, automobile exhausts.
Brass Surface finishing in apparatus and machine construction. Coating may be applied on shaft or rolls, eliminating use of solid brass.
Monel For anti corrosion applications.
01 NICrB A nickel based coating which incorporates extremely hard particles in a hardened matrix. May be used in the 'as sprayed' state although it can be subsequently fused to form a pore free coating that is metallurgically bonded to the substrate. 550 HV As Sprayed Ground Excellent
02 Ni AIMo Produces extremely dense self bonded coatings with low oxide content and low porosity. Coatings are readily machinable and grind to an excellent finish. Rb 80 Ground Excellent
03 Hi C
Provides a dense coating that is somewhat harder than METALLISATION 60E. 450 Hv Ground Excellent
04 FeCrB Produces a hard, dense coating with almost no oxide content. Work hardens and grinds to an excellent finish. The hardest of all iron based materials. Rc 55 Ground Excellent
05 FeCrC Self bonding hard coating which may be used to give excellent non-skid textured surfaces or be used as wear resistant ground coating. Rc 60 As Sprayed Ground Good
06 FeCrMoAI A self bonding material producing a machinable coating giving good wear and corrosion resistance. Rb 80 Machine Excellent
07 FeCrTiC Finely dispersed carbides give extremely high wear resistance. The spherical form of the carbide gives less likelihood of counterface damage and reduced friction. Rc 50 (Carbide Rc 70) Ground Good
08 WC/Co in
a dense coating with TUNGSTEN CARBIDE particles embedded in a hardened steel matrix. Unlike nickel based materials, this is not suitable for corrosion resistant applications. 480 Hv Ground Fair
09 CuSN A Ductile Bronze Coating. Rb 29 Machine Excellent Ground Good
10 NiaI FLAMEBOND A high performance nickel Aluminium for use FLAMESPRAY BONDING as an alternative to 99E Molybdenum where Metallisation equipment is not available. N/A As Sprayed
Our broad product line of MCrAlYs, alloys of nickel, cobalt, iron, tungsten carbide, chromium, carbide, ceramic oxides, cermet and other metal alloy powders in required particle size, coupled with unparalleled powder customization capabilities, meets almost every thermal spray powder requirement, large or small.
Thermal Spray Powders
Material Code Description Applications
MWC-1037A Ni-Al 95/5 Excellent bond coat under ceramic and metal coatings. Resists temperature to the order of 1500°F. Minimum oxide inclusions and moderate corrosion resistance. Used also for thick over lays. Good for rebuilding of worn out parts. Machinable and grindable.
MWC-1087A Ni-Al-Mo Good bond strength. Mild to moderate wear resistance. Harder than MEC-1037A due to the present of small quantity of molybdenum. Good for general repair of carbon steel and alloy steel components. Machinable with good finish.
MWC-1017A Ni-Cr This is an excellent bond coat under ceramics gives dense, clean and bright coating which resists oxidation and corrosive gases. Good for hot atmosphere to 1800°F.
MWC-1047A Ni-Cr-Al Good heat and oxidation resistance under corrosive gases. Also used normally as bond coat material for thermal barrier coatings. Specially used for rebuilding of Ni and Ni-alloyed components. Thermal stability up to 1800°F.
MWC-1044A Ni-Al-Cr-Fe-Mo Self bonding material. Good wear and oxidation resistance upto 1600°F. It is machinable to good finish.
MWC-2000A Fe-Al One step, self bonding material thermal stability is upto 350°F. Cheaper than Ni-based bond coats. Can also be used for thicker coatings. Most suitable for rebuilding and reclamation of ferrous components.
MWC-2003A Ni-Cr-Fe-Si-B/Ni-Al Hard, abrasion and wear resistance coating. Thin and thick overlays are possible. Suitable for bearing areas subjected to severe friction.
MWC-2448A Fe-Al-Mo-C 80/10/1/Low One step bonding material. Good for salvage and build-up of carbon steel components. Hard coating with good abrasion resistance. Machinable to good finish. Cheaper than MEC-1087A.
MWC-2449A Fe-Al-Mo-C Same as above with more carbon. One step self bonding material. Wider hardness range achievable. Good ground finish.
MWC-1090A Cu-Al Aluminium bronze coating with low shrinkage and less oxides. Resists cavitations, fretting and low temperature wear on hard surfaces. Machinable to good ground finish.
MWC-2052A Al-Si Good corrosion resistance. Harder, denser and gives fine texture. Machinable to good ground finish.
MWC-2404A Ni-5Al Reclamation of mis-machined or worn out parts of low carbon steel, stainless steel, brass, aluminium alloys. Machine bed ways, wear rings, press fits, bearing seats, preferably as a top coat over bond coat powder MEC-1037A.
MWC-1031C WC-Co / Ni-Cr-Si-C 35 / 65 This is a self fluxing powder, provides a dense and essentially pore free coating resists wear due to abrasive grains hard surfaces, erosion and fretting at temperature upto 1000°F.
MWC-1032C WC-Co / Ni-Cr-B-Fe-Si-C 80 / 20 Dense, hard and wear resistant coating. Thermal stability upto 1000°F. Smooth finish and no thickness limitation, if cooled slowly.
MWC-1032F WC-Co / Ni-Cr-B-Fe-Si-C 80 / 20 Dense, hard and wear resistant coating. Thermal stability upto 1000°F. Smooth finish and no thickness limitations, if cooled slowly. 
MWC-1034F WC-Co / Ni-Cr-B-Fe-Si-C 50 / 50 This is a self fluxing powder and provides coating requiring a grinding operation. Coating resists wear by abrasive grains, erosion and fretting.
MWC-1010A Al2O3 98% Hard, wear and corrosion resistant coating. Resists heat from molten metal and wear by natural abrasives.
MWC-1011A Al2O3 - TiO2  97 / 3 Same as above but more dense coating with good finish.
MWC-1051A Al2O3 - TiO2  87 / 13 A composite coating that is dense, hard and resists wear due to abrasion, fretting, cavitations and particle erosion.
MWC-1070A Al2O3 - TiO2  60 / 40  Good resistance to low temperature wears due to abrasion, fretting erosion. Grinds to low RMS. Resists wetting by liquids.
MWC-2410A Ni-Al-Al2O3 Better bonding on metallic substrates. Excellent wear and corrosion resistance.
MWC-1025HP Cr2O3  Hard & wear resistant coating, Buffing and polishing fixtures,  pump seals, plungers, wear rings, diesel engine cylinder liners, exhaust, textile components, anilox rolls etc.
MWC-1230A Ni-Fe-Si-B 94.2 / 1 / 3.2 / 1.6 Produces dense coating with hardness range from 26 - 32 Rc.
MWC-1240A Ni-Cr-Fe-Si-B 83.4 / 9 / 3 / 3 / 1.6 Produces dense coating, essentially pore free. Highly wear and corrosion resistant. Less susceptible to cracking on hardenable steels also. Good ground finish. Hardness range from 33 - 40.
MWC-1250A Ni-Cr-Fe-Si-B 78.4 / 121.5 / 3.0 / 3.7 / 2.4 Produce dense, essentially pore free. Highly wear and corrosion resistant. Less susceptible to cracking on hardenable steels also. Good ground finish. Hardness ranges from 45 - 50 Rc.
MWC-1260A Ni-Cr-Fe-Si-B 73.9 / 14.5 / 4.3 / 4.3 / 3 Produces hard, dense and pore free coating that resists corrosion and wear by abrasive grains, hard surfaces, cavitations and erosion in both high and low temperatures. Fine as sprayed finish and excellent ground finish. Hardness range from 55 - 62 Rc. 
MWC-1263A Ni-Cr-Fe-Si-B-Cu-Mo 66.3 / 14.5 / 4.3 / 4.3 / 3.1 / 12.5 / 2.5 Produces hard, dense and pore-free coating that resists corrosion and wear abrasive grains, hard surfaces, cavitations and erosion in both high and low temperatures. Fin as sprayed finish and excellent grinding finish. Hardness range from 58 - 63 Rc.
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