Bonding for Wire Flame Spray using Aluminum pure wire
12-10-2012, 02:10 AM,
Bonding for Wire Flame Spray using Aluminum pure wire
dear all,
please let me know if anyone have any experiences using Al pure for bonding instead of NiAl 80/20 , since the bonding strength Al pure is high enough, or Aluminum Bronze also can be used ?
Thanks in advance
Thanks & Regards,
Iwan Sedaryawan - Website :
12-10-2012, 03:08 AM,
RE: Bonding for Wire Flame Spray using Aluminum pure wire
Hi Iwan

Flame sprayed aluminium and aluminium bronze will not make for a good bond coats on metal substrates (relatively poor bond strength, no "self-bonding"). You would probably be better off not having a bond coat. NiAl is hard to beat and really recommended where a bond coat to metal substrates is required.

The only exception may be for heat sensitive substrates (like plastics) where aluminium and other lower melting point materials could provide good base coats for higher melting point top coats. I would certainly not recommended NiAl for temperature sensitive substrates.
12-10-2012, 07:07 PM,
RE: Bonding for Wire Flame Spray using Aluminum pure wire
Hi Iwan
I agree with Gordon, and I want to add some think else, aluminum arc spray coating can reach a coating bond strength at least 22 MPa, and with aluminum bronze you can obtain a bond strength higher than Ni/Al (about 56 MPa), but this only if you use arc spray system, I usually recommend to use bronze aluminum as bond coat for copper conductive coatings, bearings, I always obtained a good bond strenght, but i do not recomend to use aluminum wire as bond coat.
Best regards
12-14-2012, 08:00 PM,
RE: Bonding for Wire Flame Spray using Aluminum pure wire
As has been mentioned by the others bond wires are bond wires for a reason. You'll notice that the bond wires are composed of multiple metals. These compositions have been created to optimize reactivity between the constituents while spayed in order to manipulate the temperature and phase of the sprayed particles, thus creating the best possible bond.

That said, every project has its own variables, and if you can prove that using the aluminum does not take away from the performance of your coating, then it isn't a bad idea to ask the question. If you are going to try to make a change like this though, be sure that you have the understanding of the application and the laboratory tools that you will need to prove that it is a viable solution before you make a change. Usually higher bond strength is better, and the bond wires are going to give you a better bond.

Sometimes thinking outside of the box can lead to very interesting and very desirable outcomes. I once conviced a customer to change a specification from pure molybdenum to a far less expensive, easier to manipulate material, because I was able to prove comparable performance at dramatically reduced price. The result was exclusive approval to perform the new specification and a substantial influx in work. Wink

Possibly Related Threads…
Thread Author Replies Views Last Post
  Want consumables for Metco 16E combustion wire system. Turbo Machinery 0 1,173 06-07-2019, 12:11 PM
Last Post: Turbo Machinery
  Oxy-fuel wire spray gun questions hje 5 2,748 01-26-2019, 05:58 PM
Last Post: plasmajet1990
  Wire with dark colour finish pcdmt 0 1,170 12-04-2018, 09:23 AM
Last Post: pcdmt
  Application advantages of flame wire vs arc wire velocity 1 1,607 07-03-2018, 09:53 AM
Last Post: Stephen Booth
  SS 321 wire for Metallisation ehasan 10 11,156 06-07-2018, 02:14 PM
Last Post: Wagner Martines
  MO wire spray parameter for 3GF kim jong hun 2 2,180 04-29-2018, 01:00 PM
Last Post: kim jong hun
  Substrate preparation VS bonding strength plzc126330 2 2,436 01-09-2018, 03:48 AM
Last Post: plzc126330
  Mo wire spraying Arturas 6 3,039 09-15-2017, 01:29 PM
Last Post: Arturas
  Coating on Boiler tube in Coal Fired Power Plan by using Tafa wire 97MXC Iwan Sedaryawan CA 4 4,792 04-21-2017, 03:17 PM
Last Post: J!m
  difference between wire fed and powder thermal sprayers. wildlife360 4 3,250 04-13-2017, 05:22 PM
Last Post: loriolo
  Propeller shaft repair by flame spray in the cones area Iwan Sedaryawan CA 1 2,250 12-09-2016, 04:56 AM
Last Post: Stephen Booth
  Flame spray guns 5P, 5PII, Type N Hector Monjardin 1 2,838 11-17-2016, 10:35 PM
Last Post: mgbaca
  HVOF 88 WC-12Co Cracking problem on wire drawing capstan Hector Monjardin 7 5,521 10-19-2016, 11:55 PM
Last Post: Hector Monjardin
  Bonding coating for Cast steel subsrate plzc126330 5 4,375 08-15-2016, 09:01 AM
Last Post: plzc126330
  Wire drawing cracking problem Hector Monjardin 3 3,953 06-23-2016, 05:37 PM
Last Post: Hector Monjardin

Users browsing this thread: 1 Guest(s)

Surface Engineering Forum Sponsor - Alphatek Hyperformance Coatings Ltd