Thermal Spraying Processes

Wire Flame Spray


The process is basically 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) & atomised using compressed air to form a fine spray. When the spray contacts the prepared surface material, the fine molten droplet rapidly solidify forming a coating.

Characteristics of Wire Flame Spray :

Material Form Wire
Heat Source Oxy-Fuel Combustion
Flame Temperature (°C) 3000
Particle Velocity (m/sec) < 300
Porosity (%) 10 to 15
Coating Adhesion (MPa) 14 to 21

Advantages :

  • Simple to operate
  • Wire form cheaper than powder
  • Very high deposit efficiency
  • It has a portable system and can be used in areas without electricity
  • Possibly still best for applying pure Molybdenum coatings

Disadvantages :

  • Limited to spraying material supplied in wire or rod form
  • Coatings have higher porosity and lower bond strength
  • Not capable of spraying low oxide, high density & high strength coatings


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