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Wire Flame Spray

The Combustion Wire Thermal Spray Process is the spraying of molten metal onto a surface to provide a coating. Material in wire form is melted in a flame (oxy-acetylene flame most common) and atomised using compressed air to form a fine spray. When the spray contacts the prepared surface of a substrate material, the fine molten droplets rapidly solidify forming a coating.

Characteristics of wire flame spraying process coatings

  • The subjects to be sprayed are not affected by high temperature, which keeps the dimensional stability and morphological stability, causes no cracks, no strength reduction.
  • The coating with broad range of its thickness is available.
  • The coating contains harder particles than those of original materials and hard ingredients including metal oxide, nitride, carbide and etc., which provide high level of wearing resistance.

Common materials Sprayed

  • Zinc and aluminium for anti-corrosion cathodic coatings on steel
  • Nickel/aluminium composite wire for bond coats and self-bonding coatings
  • Molybdenum for bond coats
  • Molybdenum for hard bearing applications, excellent resistance to adhesive wear, used on piston rings, syncro mesh cones and journals.
  • High Chromium steel for many applications requiring hard and wear resistant coating
  • Bronzes, Babbitt for bearing applications
  • Stainless Steels, Nickel and Monel for anti-corrosion and wear

Advantages for Wire Flame Spray

  • The cost of the Wire Flame spray system is less as compared to other thermal spray processes.
  • Our Wire flame spray system is simple and easy to operate.
  • The Wires are generally cheaper than powder.
  • The process gives a high deposit efficiency.
  • Possibly still best for applying pure molybdenum coatings for wear-resistant coatings.
  • Metal Coat wire flame spray system is portable and can be carried anywhere with ease.
  • It is possible to use the system in areas without electricity supply. Only compressor is electrically powered.
  • Little operator training is necessary to use the equipment.
  • Flame spraying equipment is portable and suitable for manual use without the need for mechanised manipulators.

Metal Coat - Wire Flame Spray Equipment Manufacturer

Metal Coat has applied its engineering excellence and vast knowledge of thermal spray technology to develop a complete line of wire flame spray guns for thermal spray applications. We have been manufacturing thermal spray equipment and coating systems for over 30 years now, and hence we are undoubtedly experts at thermal spray equipment manufacturing. Our product range of wire flame spray equipment comprises of air turbine-driven models – 11M, 12M, and 14M Wire Flame Spray Equipment; and electric motor driven models – 5KM, 11ED, and 12ED Wire Flame Spray Equipment. Our wire flame spray systems are designed for both manual and automatic applications. Although Wire Flame spray systems are operated manually for most of the applications, if required, it is possible to semi-automate or completely automate our systems. We also keep a big stock of our thermal spray spare parts for the immediate needs of our customers. Please see below our wire flame spray equipment range for more details. You can find the brochures of all the models on the product page.

Wire Flame Spray Equipment

Metal Coat provides a wide variety of wire flame spray equipment that supports our clients’ diverse needs. Our 11M, 12M, and 14M Wire Flame Spray torches are air turbine-driven, whereas 5KM, 11ED, and 12ED are electric motor driven. Our 11M Wire Flame Spray is designed to spray soft and low melting wires efficiently, whereas 12M and 14M can be used to spray both soft and hard wires. The only difference between the two is that in 12M wire flame spray equipment, the wire drive is regulated through a cam lever, whereas in 14M Wire Flame Spray equipment it is thumb fed hence making the start/stop operation easier. Our 5KM Wire Flame spray system is specially designed for robust and high-volume production in an automated environment. 11ED Wire Flame gun is designed to spray low melting point soft wires. The wire feed is monitored using a DC powered motor. Our 12ED Wire Flame Spray gun can be used to spray high melting point, hard wires. It is operated by an AC powered motor. All our electric drive models have a significantly a smaller number of components that the air turbine powered models, thereby facilitating easy usage, with less downtime. Our wire flame spray equipment typically uses acetylene as fuel gas. Where acetylene is not available, our propane systems can be used for wire flame spray coatings.

Our Wire Flame Spray Systems

5KM Wire Flame Spray Gun

Suitable for high volume production in an automated environment
  • The Metal Coat 5KM Wire Combustion Gun is driven by a powerful constant-speed motor that provides precise control of wire speed and is ideally suited for automated high-volume production spraying.
  • This wire flame spray gun has constant motor control over a wide range for uniform wire feed.
  • This system is very durable with stable operation.
  • The 5KM Wire Flame Spray operates reliably and economically, with minimal downtime.
  • When a heavy-duty gun is required for high-volume or continuous combustion wire flame spray production, the Metal Coat 5KM gun provides excellent performance.
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11M Wire Flame Spray Gun

Suitable for spraying of low melting point soft wires
  • The Metal Coat 11M Wire Flame Spray Gun is designed to run at high speeds.
  • This allows the user to easily coat soft wires to any substrate efficiently and economically.
  • This gun is convenient for hand-held or start/stop operation due to the wire feed thumb trigger.
  • Our 11M Wire Flame Spray cannot spray hard wires. Metal Coat manufacturers 12M Wire Flame Spray Gun and 14M Wire Flame Spray Gun for coating of both hard and soft wires.
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12M Wire Flame Spray Gun

Suitable for spraying of both high and low melting point wires
  • The Metal Coat 12M Wire Flame Spray Gun is one of the most versatile wire flame spray equipment used for combustion wire flame spray.
  • This equipment can be used to spray both low melting and high melting wires easily.
  • It can be set up in two speeds – standard and high. Standard speed is optimum for spraying hard and high melting wires, where as high speed is used for spraying soft and low melting wires such as Babbitt, Zinc, Tin etc.
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14M Wire Flame Spray Gun

Suitable for coating both high and low melting wires
  • Our 14M Wire Flame Spray Gun is similar to 12M Wire Flame Spray Equipment, the only difference is of wire feed mechanism.
  • Here, the wire drive is thumb fed for easier start/stop operation.
  • 14M Wire Flame Spray Gun can be used to spray both low melting and high melting wires easily.
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11ED Electric Drive Wire Flame Spray Gun

Suitable for spraying of low melting point soft wires
  • Metal Coat 11ED Wire Flame Spray Gun powered with a DC electric motor.
  • It is the best in class gun used for spraying soft wires such as aluminium, zinc, lead, babbitt etc.
  • The wire drive is through an electric motor, which minimises the wire drive speed variations resulting in better coatings.
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12ED Electric Drive Wire Flame Spray Gun

Suitable for spraying of high melting point hard wires
  • Metal Coat 12ED Wire Flame Spray is powdered with an AC motor which results in constant wire feeding.
  • It is suitable to spray hard and high melting wires such as Molybdenum, Stainless Steel, Mild Steel etc.
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FAQ's

Our 11M is preferred for spraying soft wires such as Zinc, Aluminium etc. Here the wire drive is thumb operated. Our 12M and 14M Wire Flame Spray guns are versatile, it can be used to spray both soft and hard wires. In 12M, the wire drive is by cam lever whereas in 14M it is thumb fed for easier start/stop operation.
Our 12M and 14M can be provided with two speed options, namely standard and high speed. The selection should be made based on the material to be coated. Buyer should specify their requirement.
We provide two types of speed options in 12M and 14M Wire Flame Spray gun, i.e. high speed and standard. For spraying soft wires at relatively high speed, we suggest high speed setup, on the other hand for spraying hard wires, standard set is recommended.
Only the Nozzle and Siphon plug needs to be changed. Rest all the same parts may be used.
Drive Roller, drive gear and snubber assembly needs to be changed according to the new required wire size.
Application were heavy duty gun is required, 5KM is a perfect choice. The parts are rugged, meaning even with minimal maintenance it will function perfectly. It requires a very less wire drive maintenance. It is not recommended for hand working; it is designed only for robot mount or machine operation.
In Metal Coat ED Gun, the drive is through electric motor. Here the variation in speed is very minimal as compared to air drive, where there is a slight variation in speed. Hard wires can be sprayed very easily using ED Gun. Speed control is very precise and perfect. It can be using while hand held, robot mount or machine mount.
We, at Metal Coat started our journey way back in 1988 are one of the leading manufacturers and suppliers of a vast array of Thermal Spray Equipment and Coating Systems.
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