Choose your country / language

Combustion wire spray is often used to produce anti-corrosion coatings and dimensionally restore surfaces. Metal-based wires are used in-shop or on-site for coating large steel structures, such as chemical / petroleum tanks and pipelines, and for marine applications. The simple equipment requirements make it a popular choice for everything from on-site work to high-volume production in-shop.

Key benefits of this process

  • Low equipment investment costs 
  • Portability for on-site coating jobs 
  • High spray and application rates with low fuel gas consumption 

Typical applications of Combustion Wire Spray

  • Steel structures
  • Transport pipes
  • Storage tanks
  • Automotive pistons
  • Restoration of damaged surfaces

Process description

The feedstock material, in wire form, is continually fed into a fuel gas-oxygen flame where it is melted by the heat of that combustion. The fuel gases generally used are propylene, propane or acetylene. Compressed air surrounds the flame and atomizes the molten tip of the wire. This accelerates the molten particles towards the prepared workpiece surface. Combustion wire spray is a common choice for machine element repair and general corrosion-resistant coatings. 

Process basics

  • Heat source: combustion
  • Feedstock: wire (metal)
  • Flame temperature: approx. 3 100 °C (5 600 °F)
  • Particle velocity: up to 200 m/s (650 ft/s)
  • Approximate application rate: 15 to 1 400 g/min (2 to 185 lb/h)