What Is Thermal Spray Wire?


Thermal spray wires are integral to electric arc and combustion (flame) wire spray coating processes, making their selection essential. Quality wire with tight compositional tolerances must be properly spooled to achieve consistent performance and guarantee repeatable results. Uncover the best info about 45ct spray wire.

Combustion wire spraying is an increasingly popular method for corrosion protection and surface restoration of large steel structures. The process uses two metallic wires to atomize and accelerate powdered coating material onto a workpiece.


Thermal spray wire, also called arc spray or metalizing wire, serves as the feed material for electric arc spray and flame wire (combustion wire) spraying processes, making this type of wire suitable for an array of coating applications with various alloys and diameters available for purchase.

Flame and arc wire spraying techniques are two popular industrial processes for hard-facing, corrosion protection, and dimensional restoration applications. Each technique has unique capabilities that may make deciding between them difficult; their primary difference lies in how they deposit deposition material to work surfaces.

At a flame spray application, feedstock metal is heated by an oxy-fuel combustion process (using oxygen and either acetylene or propane as fuels) before compressed air jets entangle molten deposition material droplets that accelerate them towards their target substrate to form metallic coatings on it.

An arc wire spray gun uses an electrical arc to melt metal feedstock before propelling it towards its substrate with compressed air, offering greater productivity than flame spraying while offering higher bond strengths and faster application speed.

Arc spray applications utilize various alloys, such as tungsten carbide, nickel, bronze, and silicon aluminum. The type of metal chosen depends on its characteristics, such as corrosion resistance or mechanical strength; selecting one could take some trial-and-error before being chosen as a suitable material.

The diameter must match your gun setups for optimal thermal spray wire performance. In addition, compositional tolerances must be tight while spooling correctly for consistent diameter control.

Quality thermal spray wire is also crucial, as its performance determines the performance of any applied coatings. To ensure you obtain only high-grade coatings, look for thermal spray wire manufactured according to stringent standards and undergoes strict testing and inspection processes.


Various materials are used for thermal spray wire production, and their choice will depend on your intended application. Flame and twin wire arc (sometimes known as electric arc or combustion wire) spray are two primary categories of thermal spraying; flame spraying uses oxygen and acetylene gas mixtures to heat feedstock material, while electrical arc spray uses an electrical current arc – this melts deposition material, creating fine droplets which travel toward the substrate to coat them.

Metals and alloys of various kinds may be sprayed using either technique, though their application is restricted to those that can be formed into malleable wires due to manufacturing methods used to produce thermal spray wire – forging or hot rolling of raw material into intermediate sizes before cold drawing using complex dies; hard or brittle materials cannot be cold drawn to produce thermal spray wires.

Metallic thermal spray wires, typically constructed of aluminum or nickel, are commonly used to produce various protective and functional coatings for protection, wear resistance, and dimension restoration applications. Some such applications could include corrosion prevention, wear resistance, or restoration of worn components.

Other types of wires made from ceramic materials like zirconia and tungsten carbide are also available; these may be used to produce coatings with specific properties, such as thermal insulation or electrical conductivity.

The spooling process for thermal spray wire should also be considered, with its final spooling preventing kinks or any defects hindering its use in production processes. Furthermore, an even distribution should be ensured.

Thermal spray gun systems come in various varieties, from mechanical feed systems that feed both wires simultaneously to “push/pull” systems that pull wires through one at a time. No matter which method is chosen, quality wire explicitly made for thermal spray should always be utilized that has been produced with precise metallurgical composition and is free from silvers or contaminants.


Thermal spray coatings are used in many industries to reduce corrosion, restore dimensions, or protect against impact, abrasion, or wear. Their applications range from aerospace components and automotive vehicles to oil rigs and lumber mills, but one key to their use lies with the wire feedstock of their spray guns: thermal spray wire is designed specifically for use in this coating system and features tight compositional tolerances that guarantee specific metallurgical characteristics are met.

The Arc Wire Thermal Spraying process is one of the most widely used and efficient means of applying metals or alloys to surfaces. The method relies on two metallic wires that atomize into droplets propelled onto surfaces as coatings. This approach has long been employed, creating dense and robust layers. Furthermore, its cost-effective nature makes it safer than many other spraying techniques.

Rolls are essential components in various industrial operations, yet they often experience excessive wear due to their harsh operating environments. This wear can reduce quality production from machines and, in extreme cases, may necessitate replacement rolls – however, arc wire thermal spraying provides an effective means of prolonging their lifespan while keeping production going as efficiently as possible.

Flame spraying is another efficient method for applying metals to surfaces. This process uses an oxygen/acetylene flame as the medium through which metal wire is passed; when heated by this flame, it melts the wire, which enters an air jet from a spray gun before being accelerated with compressed gas to form a coating on substrates.

Numerous companies produce thermal spray wire, each offering its own capabilities regarding materials it can handle and coatings it can create. For instance, some manufacturers provide cored wires designed to work in an arc spray system, which allows compositions that cannot be drawn as solid metal to be created by enclosing powders within metallic sheaths. These specialized wires come in different diameters to meet specific application requirements, including coating chemistry and thickness requirements.


Thermal spraying requires wires that meet stringent size and composition requirements in terms of size and diameter, free from contaminants like silver. Furthermore, they must be made from metals or alloys capable of withstanding high temperatures and rapid decomposition required to liquefy deposits before being propelled onto substrates in a controlled fashion to form functional coatings.

Thermal spray coating is an efficient and cost-effective method of improving components, structures, and equipment performance. It offers numerous advantages, including wear resistance, corrosion protection, and dimension restoration. Two primary methods include flame spraying and wire arc spraying – while their operational principles may seem similar at first glance, there can be considerable variances in how each technique operates.

Flame spraying involves feeding feedstock into a heated flame in wire or powder form. A stream of compressed air then accelerates droplets of deposition material toward a substrate to coat it – it is the most frequently employed application of flame spray, capable of laying down very thick coatings.

Wire arc spraying differs from flame spray in that the feedstock is heated using an electrical arc rather than flames, formed between two electrically charged metallic wires in the spray gun. A compressed air stream then atomizes molten metal from each wire’s tip and propels it toward its target surface – producing thinner coats but providing the same benefits.

Wire arc spraying offers several advantages over flame spraying: lower system costs, portability, and less expense than flame spraying and the use of different metals – such as those that cannot be cast into solid wire – than love spreading. It has revolutionized industrial applications.

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