Thermal Spray Wires

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Thermal

Spray
Wires
Dura-Metal offers the highest
quality wire in the market for both
Twin Wire Arc Spray (TWAS) and
Flame Spray operations.
We offer over 30 specialized
alloys for Thermal Spray
application.
www.durametal-alloy.com

BASE
DM GRADE DESCRIPTION HARDNESS
MATERIAL

A PROPRIETARY SELF BONDING, HARD, ABRASIVE & CORROSION RESISTANT ARC


SPRAY WIRE. Less fumes and higher DE compared to standard amorphous material
HardBond during spraying. Applications: used as protective coatings on yankee dryer roll, exhaust
Iron 65 HRC
TWAS fan, steel rolls and applicable in a wide variety of high abrasive and corrosive wear
operating environments.

A PROPRIETARY HIGH HARDNESS ARC SPRAY WIRE DESIGNED FOR BOILERTUBE


BoilerShield PROTECTIVE COATINGS. Coatings exhibits high bond strength and good abrasion,
Iron erosion & corrosion resistance at elevated temperatures. Emit less fumes and higher 63 HRC
TWAS
deposition effiency compared to standard amorphous material during spraying.

A SPECIALLY FORMULATED CO-SPRAY ARC SPRAY WIRE DESIGNED FOR HARD


PROTECTIVE COATING & GOOD SURFACE FINISH. Good bond strength, abrasion
HardBond and corrosion resistance alloy combination. For dimensional restoration and corrosion
+ 28 Cr Iron protection. Well suited for Cr-plating of hydraulic cylinder rods, piston rods, sleeves 58 HRC
TWAS and rollers, etc. Suitable for use as a HVOF coating replacement for a variety of
applications.

AN ECONOMICAL SELF BONDING CORED WIRE DESIGNED FOR ARC SPRAY.


Coating exhibit unique ability to produce either smooth or rough profile. Typically used
750 TWAS Iron for anti-slip coatings for walkways, stairs, gripping rolls and part restoration. Also 35 HRC
applicable as a bond coat for general non-corrosive operating environment.

A HIGH QUALITY PROPRIETARY HARD, ABRASIVE, EROSION & CORROSION


RESISTANT CORED WIRE FOR ARC SPRAY. Excellent resistance to abrasion and
770 TWAS Iron particle erosion at elevated temperatures. Used as a protective coating on boiler tubes, 60 HRC
yankee dryer rolls, fan blades, anti-skid surfacing and applicable in a wide variety of
high abrasive and corrosive wear operating environments.

A RICH CHROMIUM CARBIDE CORED WIRE DESIGNED FOR ARC SPRAY. Coatings
exhibit good hardness that is abrasion and corrosion resistant. Finish possible by
796 TWAS Iron machining with carbide tools. Applications: boiler tubes & tube shields, fan blades and 55 HRC
mixing blades, etc.

A SPECIAL TITANIUM & TUNGSTEN CARBIDE ALLOY BLEND IN AN AMORPHOUS


MATRIX DESIGNED FOR ARC SPRAY. Produces a hard protective coating against high
797 TWAS Iron abrasion and corrosion at elevated temperatures. Applications: fan blades, boiler 65 HRC
tubes and a variety of high wear applications.

A HIGH QUALITY Fe Cr Al CORED WIRE DESIGNED FOR TWIN WIRE ARC SPRAY.
Excellent wear and high temperature oxidation resistance. Can be easily machined and
781 TWAS Iron yields a smooth finished surface. DM 781 TWAS low shrink characteristic allows thicker 90 HB
coating build up. Applications include sleeves, boiler tubes, boiler tube shields, shafts
or as a bond coat, etc.

A LOW SHRINK CHROME STEEL ARC SPRAY WIRE DESIGNED FOR DIMENSIONAL
RESTORATION. Good coefficient of friction, wearing quality and fair resistance to
420 TWAS Iron corrosion. Applications: journal sections, cylinder liners, crankshaft bearings and 40 HRC
numerous other machine elements.

A 18/8 STAINLESS STEEL GRADE ALLOY DESIGNED FOR ARC SPRAYING. Coatings
exhibits high corrosion resistance and able to withstand high temperatures.
304 TWAS Iron Applications include rams, pump sleeves, shafts seal rings, valve plugs, printing press 95 HB
transfer ink rollers and as final coating to resurface paper mill cylinders.

A 300 SERIES STAINLESS STEEL WIRE DEVELOPED FOR ARC SPRAYING. Coatings
exhibits very high corrosion resistance and excellent machinability. Applications
316 TWAS Iron 95 HB
include printing rolls, pump plungers, rams, impellers, pump sleeves, shafts, seal rings,
valve plugs and wedges.
www.durametal-alloy.com

BASE
DM GRADE DESCRIPTION HARDNESS
MATERIAL

A 18/5 STAINLESS STEEL WIRE DESIGNED FOR ARC SPRAYING. Excellent


corrosion resistance, low shrink and good machinability coating characteristics.
18-5 TWAS Iron Ability to build up thick coatings. Applications include hydraulic rams, food industry 90 HB
rollers and a variety of machine elements.

A PURE NICKEL WIRE SPECIFICALLY DESIGNED FOR ARC SPRAYING. Coatings


exhibit excellent corrosion resistance with good machinability and electrical
990 TWAS Nickel conductivity. Applications: machine element repair that require high corrosion 60 HB
resistance. Also used as corrosion protective coating in chemical processing
equipment and marine components.
A HIGH PURITY NICKEL-20 CHROMIUM WIRE DESIGNED FOR ARC SPRAY
PROCESS. Dense well bonded coatings with excellent machinability, electrical
920 TWAS Nickel conductivity and oxidation resistance at elevated temperatures (980°C/1800°F). 95 HB
Applications: machine element repair, oxidation and heat resistant coating
applications, etc.

A NiCrTi WIRE DEVELOPED SPECIALLY FOR BOILER APPLICATIONS. Coatings


exhibits superior bond strength and excellent corrosion & wear resistance. Highly
945 TWAS Nickel resistant to corrosive vanadium and sulfur gases in boiler atmospheres up to (995°C 35 HRC
/1825°F). Applications: mainly for boiler tubes in black liquor recovery boilers and
coal fired utility boilers.
A HIGH QUALITY NICKEL-5 ALUMINUM PRE-ALLOYED SELF- BONDING WIRE FOR
ARC SPRAY. Coatings exhibits high bond strength and toughness. Good corrosion
955 TWAS Nickel and oxidation resistance up to (650°C/1200°F). Used as a bond coat and for 85 HB
dimensional restoration like rebuilding nickel based alloys, machinable carbon
steels and corrosion resistant steels.

A NICKEL-20 ALUMINUM CORED WIRE DESIGNED FOR ARC SPRAYING OR


FLAME SPRAYING. Produces superior bond coats that are dense and resistant to
984 TWAS Nickel high temperature oxidation & thermal shock. Self bonding to a broad range of 80 HB
smooth metal surfaces. It is not self bonding to copper based alloys or tungsten.
Used as a bond coat or for dimentional restoration repairs.

A Ni-Cr-Al-Y NICKEL BASED CORED WIRE DESIGNED FOR ARC SPRAYING. Well
bonded and dense coatings with excellent oxidation and corrosion resistance at
987 TWAS Nickel 85 HB
elevated temperatures up to (980°C/1800°F). Applications: undercoat for ceramics
on steel, stainless steel & cast iron surfaces.

A Ni-Cr-Mo (Alloy C-276) WIRE DESIGNED SPECIFICALLY FOR ARC SPRAYING.


Produces dense, well bonded coatings with very good resistance against corrosion &
C276 TWAS Nickel stress cracking in caustic, acidic and chloride mediums. Excellent resistance to 35 HRC
abrasion and metal-to-metal wear. Applications: protective coatings for chemical
refining & manufacturing industries components such as pump casings & valves, etc.

A HIGH PURITY ALLOY 625 TYPE WIRE DESIGNED FOR ARC SPRAYING. This alloy
produces dense and well bonded coatings that are resistant to corrosion and stress
625 TWAS Nickel cracking in caustic mediums. It is also very corrosion resistant to a broad range of 95 HB
acidic and chloride environments. Applications: digestors and protective coating on
components subjected to oxidation, heat and corrosion operating environments.

AN ALLOY 718 TYPE WIRE MATERIAL DESIGNED FOR ARC SPRAYING. Produces
self bonding coatings with excellent high temperature oxidation and corrosion
718 TWAS Nickel resistance in a broad range of acidic, chloride and hot gas environments. 30 HRC
Applications: dimensional restoration of parts in power plant and oil drilling
industries, etc.

A Ni-Cu TYPE WIRE MATERIAL DESIGNED FOR ARC SPRAYING. Protective coatings
mainly for resistance to sea water corrosion and caustic operating environments in
Ni30Cu TWAS Nickel marine, petrol chemical industries. Applications: machine element restoration, 85 HB
propellers, steam valve components, printing rolls and shafts, etc.
www.durametal-alloy.com

BASE
DM GRADE DESCRIPTION HARDNESS
MATERIAL

A SELF BONDING Ni-Cr-Mo-Si CORED WIRE DESIGNED FOR ARC SPRAY. Very
good corrosion resistance particularly in sulfuric and other high sulfur operating
ChemShield-
Nickel environments. Excellent bond strength and toughness. Applications: protective 45 HRC
TWAS
coating on refineries, power boilers, chemical plant and other medium abrasive
and corrosive wear operating environments.
A SELF BONDING Ni-Cr-B-Si-Mo + HARD PHASE CORED WIRE DESIGNED FOR
ARC SPRAY. Very good abrasion, erosion and corrosion resistance particularly in
ChemShield-B
Nickel seawater and chemical environments. Also exhibits excellent bond strength and 65 HRC
TWAS
toughness. Applications: power boilers, digesters, exhaust fans, shafts and
rollers.
A HIGH QUALITY PURE ALUMINIUM WIRE MADE EXCLUSIVELY FOR ARC
SPRAYING. Protective coatings are resistant to atmospheric, chemical and sea
1100 TWAS Aluminium water corrosion. It also exhibits electrical and heat conductivity properties. 65 HB
Applications: mainly for offshore platforms.

A 99.5 % ALUMINIUM CONTENT WIRE MADE EXCLUSIVELY FOR ARC


SPRAYING. Protective coatings are resistant to atmospheric, chemical and sea
1350 TWAS Aluminium water corrosion. It also exhibits electrical and heat conductivity properties. 65 HB
Applications: mainly for offshore platforms, semi-conductor components and anti
skid coating for shipdecks.
A HIGH QUALITY Al-Si WIRE DESIGNED SPECIALLY FOR ARC SPRAYING.
Coatings attains a harder surface than standard pure aluminium. It does not gall
1043 TWAS Aluminium easily and coatings are more dense, finer texture and faster spray adhesion. Used 75 HB
for aluminium build up on worn machine parts, and repairing blow holes in
aluminium patterns.
A HIGH QUALITY 99.99% PURE ZINC WIRE DESIGNED FOR ARC SPRAY AND
FLAME SPRAY SYSTEMS. Excellent corrosion resistance and good conductivity.
4540 TWAS Zinc Used primarily for corrosion protection of steel, electrical conductivity applications 70 HB
and mold making. It is also used as a bond coat when spraying metals onto non-
metallic substrates.

A HIGH QUALITY Zn-Al WIRE DESIGNED FOR ARC SPRAY AND FLAME SPRAY
SYSTEMS. Good corrosion resistance and conductivity. Used primarily for all
984 TWAS Zinc atmospheric corrosion protection where zinc or aluminum are utilized-combining 73 HB
the advantages of both. Note that for all marine applications, a sealer must be
used.

A HIGH GRADE TIN BASED LEAD FREE BABBITT WIRE DESIGNED FOR ARC
SPRAY AND FLAME SPRAY SYSTEMS. Good toughness and machinability.
4542 TWAS Tin (Babbitt) Coatings exhibits low coefficient of friction. Used primarily to produce dense, well 70 HB
bonded coatings required for high speed and heavy duty bearings.

A QUALITY PURE MOLYBDENUM WIRE FOR ARC SPRAY OR FLAME SPRAY


SYSTEMS. Good resistance to wear and corrosion. Low coefficient of friction and
589 TWAS Molyndenum anti galling properties. Range of coating hardness can be achieved by varying air 15 - 35 HRC
pressure and stand off distance. Used for applications where scuffing and galling is
a problem such as piston rings, shift forks and synchronizing rings.

A QUALITY PREALLOYED ALUMINIUM BRONZE WIRE DESIGNED FOR ARC


SPRAY. Good bond strength and corrosion resistance properties. Coatings are
Aluminium dense and wear resistance. Applications: mainly housings, bearings, shafts and as
446 TWAS 68 HB
Bronze a bond coat for copper based alloys as the nickel aluminium bond coat does not
bond well to copper substrates.

A HIGH PURITY COPPER WIRE DESIGNED FOR ARC SPRAYING. Produces


dense, well bonded coatings with excellent machinability. It is widely used for
499 TWAS Copper electrical conductivity and printing roll applications. Other non-electrical 40 HB
applications for copper range from purely decorative purposes to elements
requiring protective coating.

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