Thermal Spray Wire

　

Various metal and alloy wires (also known as wire rods) are widely used thermal spray materials in the combustion wire spraying and electric arc spraying processes. In recent years, the successful development of composite wire and powder core (drug core) composite wire has enabled thermal spraying wire to develop from the original single metal and alloy wire to cermet and ceramic composite. In particular, the development of nano-powder core composite wire has enriched the types of thermal spraying wire.
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The basic requirements for thermal spraying wire: the chemical composition of the material and thermal spraying performance. The thermal spray performance of wire refers to the geometric size and tolerance, surface state, ductility and strength of the wire.
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Thermal spraying wire can generally be divided into: zinc, aluminum and its alloy wire; iron-based alloy (steel material) wire; non-ferrous metal and nickel-based alloy wire; composite wire, etc.
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Zinc and aluminum alloy wire materials include:
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Pure zinc wire, pure aluminum wire and zinc-aluminum alloy wire. Mainly used for long-term protection of steel components.
Aluminum-silicon alloy wire and zinc-tin alloy wire are mainly used for anti-corrosion, workpiece repair, electromagnetic shielding, etc.
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Iron-based alloy wire mainly includes: carbon steel sprayed wire and stainless steel wire.
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Commonly used carbon steel wires are: low carbon steel wire, medium carbon steel wire and high carbon steel wire. Mainly used for surface repair of steel workpieces. Carbon tool steel high-hardness wire, mainly used for spraying high-hardness and wear-resistant coatings.
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Commonly used stainless steel wires are: Cr13 series, such as 1Cr13, 2 Cr13 and 3Cr13. Cr13 material is high-carbon martensitic stainless steel, which has hardenability and good inter-particle bonding. It is mainly used for arc spraying high hardness, wear-resistant and corrosion-resistant coatings. 0Cr18Ni9Ti and 1Cr18Ni9Ti series are low-carbon martensitic stainless steel materials with excellent corrosion resistance. The coating has high cohesive strength and is easy to cut, so it is often used for repairing. This similar material also has 1Cr18Mn9Ni5N, 0Cr18Ni12 Mn 2Ti and so on.
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In addition to the zinc and aluminum materials introduced above, non-ferrous metal wire materials also include:
Copper and copper alloy wire. In addition to being used as a conductive coating, pure copper is also used for decoration. Aluminum bronze series alloys have good corrosion resistance and can be used for restoration. Due to the high tensile strength and shear strength of this coating, it is often used as a bonding primer in arc spraying. Commonly used copper alloy wires include brass wire (containing 15-23% Zn), tin bronze wire (containing 3.5-4.5% Sn, 2.7-3.3% Zn), phosphor bronze wire (containing 6-8% Sn, 0.1 ~0.25%P).
Nickel has oxidation resistance, heat resistance and corrosion resistance, and has good toughness and high strength. Nickel-chromium alloy wire has excellent heat resistance and oxidation resistance; nickel-chromium-titanium alloy also has excellent high-temperature gas corrosion resistance; nickel-copper alloy, also known as "Monel" alloy, has good corrosion resistance. The properties of nickel-based alloy wire are shown in the table below.
Commonly used nickel base alloy wire
Material
Main ingredient/%
main performance
Nichrome wire
Ni77～79, Cr19～21
It has good oxidation resistance and can work in an oxidizing atmosphere at 1200°C. It can be used as heat-resistant and anti-oxidation coating for steel parts.
Nickel Copper Alloy Wire
Cu29, Mn1.1, Fe0.9, Ni
Excellent corrosion resistance, can be used for corrosion-resistant coating of mechanical parts in corrosive environment.
Nickel-chromium-titanium alloy wire
Cr43, Ti<0.4, more than Ni
Good spraying performance, excellent resistance to sulfide and high temperature gas corrosion at 400-800 °C. Mainly used as a protective coating for boiler pipes
Nickel-Chrome Aluminum Alloy Wire
Cr15～17, Al5～7, Ni
The coating has good bonding performance, can resist high temperature oxidation and gas corrosion, and can work at 1000°C. Widely used as a bonding base.
Inconel Wire
Ni 60, Cr15, Fe
It has good oxidation resistance at 1060°C, mainly used as a high temperature resistant and oxidation resistant coating

  Composite wire generally includes: