Material Product Data Sheet Pure Aluminum Thermal Spray Wires

Material Product Data Sheet
Pure Aluminum Thermal Spray Wires
Thermal Spray Wire Products: Metco Aluminum Quick Facts

Classification Wire, pure aluminum
1 Introduction
Chemical formula 1050 Grade: 99.5 %+ Al
Metco™ Aluminum wires are drawn to a variety of diameters
1100 Grade: 99.0 %+ Al
for use in electric arc wire and combustion wire 1350 Grade: 99.5 %+ Al
Thermospray™ spray systems. The coatings produced by
Manufacture Drawn wire
these aluminum wires have a number of useful characteristics
Melting point 660 °C (1220 °F)
that include resistance to atmospheric, chemical and heat
corrosion. In addition, aluminum is a good electrical Purpose Corrosion protection and electrical
conductivity
conductor.
Process Electric Arc Wire Spray or
Combustion Wire Thermospray™
As aluminum is anodic to steel, coatings of aluminum act as
excellent sacrificial coatings on steel substrates. Further-
more, the aluminum coating tends to form an oxide film that
protects it from further attack.
Aluminum wire coatings are recommended for cathodic

corrosion protection in atmospheric and salt / fresh water
immersion, with application areas such as oil refining equip-
ment, chemical processing equipment, boat bottom interiors
exposed to bilge water and other similar types of exposure.
Thermal sprayed aluminum coatings can be applied relatively
thick and replace plating or paints, or used as an undercoat
to organic coatings and paints. Properly applied, these
coatings can last from 15 to 50 years without maintenance.
Aluminum is an excellent conductor of electricity and may be

used on aircraft fiberglass panels to disperse static electricity,
and many other applications where electrical conductivity
is desired.
1.1 Typical Uses and Applications:

nn General industry: Cathodic corrosion protection on steel
structures such as bridges and water towers, for which
the coating can be used alone or as a very good bond
and protective undercoat for organic materials
nn Aviation: Coatings on fiberglass panels for static dispersion
and corrosion protection of outer casings
nn Automotive: high temperature corrosion protection on
exhaust valves
nn Electronics: Electrical conductance on components
such as conductive areas on insulators, capacitor end
caps and varistors.
DSMTS-0003.10 – Pure Aluminum Thermal Spray Wires

© 2014 Oerlikon Metco 1
2 Material Information
2.1 Chemical Composition
Nominal Chemistry Weight Percent (nominal)

Al (min.) Cu (max.)
Metco Aluminum (1050 grade) Al 99.5+ 99.5 0.05 – 0.2
Metco Aluminum (1100 grade) Al 99.0+ 99.0 0.05 – 0.2
Metco Aluminum (1350 grade) Al 99.5+ 99.5 –
2.2 Available Wire Sizes
Available Wire Diameters Recommended Spray Process

Electric Arc Wire Combustion Wire
1.45 mm (15 ga)
1.62 mm (14 ga)
2 mm (5/64 in)
2.0 mm (0.079 in)
2.3 mm (11 ga)
2.5 mm (0.098 in)
3.2 mm (1/8 in)
4.0 mm (0.157 in)
4.8 mm (3/16 in)
Other products sized and packaged for electric arc wire or combustion wire may be available as a special order.
2.3 Key Selection Criteria nn Metco Zinc is advantageous for cathodic protection
Choose the product that is: applications in cold water, mild atmospheres where there
nn Appropriate for the thermal spray process to be used are no corrosive fumes, when thin coatings are required
(electric arc wire spray or combustion wire spray) or when coating areas are difficult to access. Coatings of
nn Available in your geographical region Metco Zinc have a better 'distance effect' as an anode
nn Packaged for the specific equipment to be used, particu- than coatings of Metco Aluminum. However, zinc cannot
larly in the case of electric arc wire systems be used in acidic environments.
nn The appropriate wire diameter for the spray gun hardware nn Metco 54NS and Metco 54NS-1 are pure aluminum
that is installed powders for the atmospheric plasma spray and combustion
powder spray processes.
2.4 Related Products nn Coatings of pure copper wire, such as Metco Copper,
nn Metco AlMg wire provides excellent protection, and is or powder, such as Metco 55 provide better electrical
preferred over Metco Aluminum in marine environments. conductivity than Metco Aluminum.
nn Metco ZnAl wire is recommended for applications where
cathodic protection is the primary concern.

2.5 Customer Specifications
Specification Certification When Origin Is:

U.S.A. Germany
American Welding Society (AWS) C2.25/C2.25M W-AL-1100 a
ASTM International B-211
Cincinnati Thermal Spray CTS 1333
GE B21B22A
Honeywell FP 5045, Type VI
Rolls-Royce plc MSRR 9507/105 b
a Applies only to 1100 grade aluminum wire.
b Applies only to 1050 grade and 1100 grade wire.
3 Coating Information
3.1 Key Thermal Spray Coating Information
Specification Typical Values

Macrohardness HRH 78 – 82
Bond Strength a MPa 7 – 30
psi 1000 – 4350
Coating Density g/cm3 2.41
Coating Porosity vol. % 1–2
Maximum Service Temperature °C 538
°F 1000
a On grit-blasted steel. Bond strength dependent on the spray process used. Values shown were determined using FM100 film. If epoxy glues are used, bond strength
values will be higher than those listed above as a result of glue penetration.
3.2 Coating Parameters Recommended Spray Guns

Please contact your Oerlikon Metco Account Representative
Electric Arc Wire Combustion Wire
for parameter availability. For specific coating application
SmartArc PPG Metco 16E Series
requirements, the services of Oerlikon Metco’s Coating
Solution Centers are available.. Metco LD/Schub 5 Metco 5K
Metco LD/U2
Metco LD/U3
Praxair / Tafa wire arc guns

4 Commercial Information
4.1 Ordering Information and Availability
Wire Diameter Order No. Package Size Package Type Availability 1 Distribution Origin
1050 Grade
1.62 mm (14 ga) 1002469 7 kg (15 lb) Wire Basket Reel Stock Europe Germany
1.62 mm (14 ga) 1066060 60 kg (132 lb) Drum Stock Europe Germany
2 mm (5/64 in) 1002451 7 kg (15 lb) Wire Basket Reel Stock Europe Germany
2.0 mm (0.079 in) 1057623 7 kg (15 lb) Hasp Spool Special Order Europe Germany
2.0 mm (0.079 in) 1002452 100 kg (220 lb) E560 Spool Special Order Europe Germany
2.3 mm (11 ga) 1066057 60 kg (132 lb) Drum Stock Europe Germany
2.5 mm (0.098 in) 1057625 7 kg (15 lb) Hasp Spool Stock Europe Germany
2.5 mm (0.098 in) 1057627 17 kg (37 lb) Hasp Spool (460) Stock Europe Germany
2.5 mm (0.098 in) 1066496 60 kg (132 lb) Drum Stock Europe Germany
3.2 mm (1/8 in) 1002494 25 kg (55 lb) Coil Stock Europe Germany
4.0 mm (0.157 in) 1069402 25 kg (55 lb) Coil Special Order Europe Germany
1100 Grade
1.45 mm (15 ga) 1030506 50 lb (22.7 kg) Coil Stock Americas U.S.A.
1.45 mm (15 ga) 1029051 225 lb (102 kg) Spool Stock Americas U.S.A.
1.62 mm (14 ga) 1031591 16 lb (7.25 kg) Dorn Spool Stock Global U.S.A.
1.62 mm (14 ga) 1036247 225 lb (102 kg) Spool Special Order Global U.S.A.
2.3 mm (11 ga) 1030507 50 lb (22.7 kg) Coil Stock Global U.S.A.
2.5 mm (0.098 in) 1068756 7 kg (15 lb) Hasp Spool Stock Europe Germany
2.5 mm (0.098 in) 1073355 17 kg (37 lb) Hasp Spool Stock Global Germany
3.2 mm (1/8 in) 1030501 50 lb (22.7 kg) Coil Stock Global U.S.A.
4.0 mm (0.157 in) 1070562 25 kg (55 lb) Coil Stock Europe Germany
4.8 mm (3/16 in) 1030505 50 lb (22.7 kg) Coil Stock Global U.S.A.
1350 Grade
1.62 mm (14 ga) 1040882 16 lb (7.25 kg) Dorn Spool Special Order Global U.S.A.
1 Minimum order quantities for special order products may apply.
4.2 Handling Recommendations 4.3 Safety Recommendations

nn Store in the original container in a dry location. See SDS 50-307 (Materials Safety Data Sheet) in the local-
nn Do not stack drums; keep drums upright and avoid ized version applicable for the country where the material
excessive vibration during transport to prevent decoiling. will be used. SDS are available from the Oerlikon web site at
www.oerlikon.com/metco (Resources – Safety Data Sheets).
Information is subject to change without prior notice.
DSMTS-0003.10 – Pure Aluminum Thermal Spray Wires www.oerlikon.com/metco

© 2014 Oerlikon Metco info.metco@oerlikon.com4

Material Product Data Sheet Pure Aluminum Thermal Spray Wires

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Material Product Data Sheet Pure Aluminum Thermal Spray Wires

Uploaded by

Copyright:

Available Formats

Material Product Data Sheet

Pure Aluminum Thermal Spray Wires

Thermal Spray Wire Products: Metco Aluminum Quick Facts

Aluminum wire coatings are recommended for cathodic

Aluminum is an excellent conductor of electricity and may be

1.1 Typical Uses and Applications:

DSMTS-0003.10 – Pure Aluminum Thermal Spray Wires

2.1 Chemical Composition

Nominal Chemistry Weight Percent (nominal)

2.2 Available Wire Sizes

Available Wire Diameters Recommended Spray Process

DSMTS-0003.10 – Pure Aluminum Thermal Spray Wires

Specification Certification When Origin Is:

3.1 Key Thermal Spray Coating Information

Specification Typical Values

3.2 Coating Parameters Recommended Spray Guns

DSMTS-0003.10 – Pure Aluminum Thermal Spray Wires

4.1 Ordering Information and Availability

4.2 Handling Recommendations 4.3 Safety Recommendations

Information is subject to change without prior notice.

DSMTS-0003.10 – Pure Aluminum Thermal Spray Wires www.oerlikon.com/metco

You might also like