Thermal Spray Coatings: WIRE_ARC
Properties of thermally sprayed coatings by spray process and coating material. Processes: HVOF (high velocity oxy-fuel), APS (atmospheric plasma spray), wire arc spray, detonation gun, and cold spray. Materials: WC-Co and Cr3C2-NiCr carbide cermets, Al2O3/Al2O3-TiO2/Cr2O3/ZrO2-YSZ oxide ceramics, MCrAlY bond coats, NiCr, Stellite 6, 316L stainless, copper, zinc, aluminum, and specialty alloys. Properties: hardness (HV), bond strength (MPa), porosity (%), oxide content (%), surface roughness Ra (um), deposition efficiency (%), thickness range, max service temperature, wear rate, and application guidance. Per ASM Handbook Vol 5A and Oerlikon Metco/Praxair/Höganäs product data.
| spray process | coating material | application | bond strength mpa max (MPa) | bond strength mpa min (MPa) | bond strength mpa typical (MPa) | deposition efficiency pct max | deposition efficiency pct min | deposition efficiency pct typical (%) | hardness hv max (HV) | hardness hv min (HV) | hardness hv typical (HV) | material category | max service temp c (degC) | oxide content pct max | oxide content pct min | oxide content pct typical (%) | porosity pct max (%) | porosity pct min (%) | porosity pct typical (%) | surface roughness ra um max | surface roughness ra um min | surface roughness ra um typical (um) | thickness range um max (um) | thickness range um min (um) | wear rate relative |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| WIRE_ARC | 316L_SS | Stainless wire arc; corrosion; repair/restoration; lower bond strength than HVOF; economical corrosion protection | 30 | 12 | 20 | 75 | 55 | 65 | 280 | 150 | 200 | metallic | 750 | 25 | 5 | 15 | 18 | 4 | 10 | 18 | 8 | 12 | 600 | 100 | high |
| WIRE_ARC | Aluminum_99 | Sacrificial + barrier protection; marine; petrochemical; higher temp than zinc; offshore structures; NACE/AWS standards | 21 | 7 | 14 | 85 | 65 | 75 | 60 | 30 | 40 | metallic | 650 | 35 | 5 | 20 | 22 | 5 | 12 | 18 | 8 | 12 | 500 | 50 | high |
| WIRE_ARC | Copper_Al_Bronze | Aluminum bronze wire; bearing surfaces; marine; bearing shaft repairs; bushing restoration; seawater corrosion | 30 | 12 | 20 | 80 | 60 | 70 | 280 | 150 | 200 | metallic | 450 | 28 | 5 | 15 | 18 | 4 | 10 | 18 | 8 | 12 | 600 | 100 | medium |
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