Gordon England Surface Engineering Forum



Re: Thermal spray and fuse forming (wire combustion type)


Posted by Gordon England on March 24, 2004 at 10:09:56:

In Reply to: Thermal spray and fuse forming (wire combustion type) posted by Nathanael on January 12, 2004 at 06:46:36:

: I have many projects that I could use such a beast for, not the least of which is EDM electrode forming, possibly free-standing thin-walled components as well. My question is, is it possible to ATTAIN the WROUGHT PROPERTIES of the sprayed material with adequate fusing (and possibly fluxing) of the sprayed coating? System would be a Metco 12E with oxy/acetylene, and an oxy/acetylene torch for fusing. Spray-formed components approx. 2mm max thickness. Components would be fairly small, like 6"x12" area, I don't care if I have to stand there with a torch for 2 hours (it would still be saving me countless hours of headaches and costly labor), I just want to know if it can be done with that equipment, and what fluxes, shielding gases etc. I would need, if any. The key is to attain the wrought properties, ie ~ ELIMINATE ~ oxide inclusions, porosity, and stresses. Thanks mates!

: Nathanael

Hi Nathanael

I don't think this process would be an easy set-up for your application. Commercial self-fluxing materials are based on NiCrBSi alloys and are normally only produced in powder form which would only suit the 5P-II gun. The coatings would have to be sprayed on to a solid compatible substrate. This would require machining away after fusing.

Whether the final product would meet with your property requirements is difficult to know. I suspect not. I would try some experiments using the 5P-II gun and a material like Metco 12C and I think you will quickly see whether this root is worth pursuing.


Hope this helps

Regards Gordon


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