Combustion wire metallizing is a thermal spraying process and is used to create coatings for base materials to enhance their exterior mechanical or chemical attributes. Combustion wire metallizing involves an oxygen fuel flame, a consumable wire and a pressurized gas.
Combustion wire metallizing may also be known as flame wire spraying.
The combustion wire metallizing process fundamentals are relatively simple. First, an oxygen and fuel gas mixture is released from a torch. The mixture is then ignited. A consumable wire is fed into the oxygen fuel flame. The heat from the flame melts the wire.
A compressed gas, usually compressed air, is used to atomize the molten material into fine particles to help with adhesion. The compressed air is also used to project the fine particles at the base material. The consumable material adheres to the base material's surface and a coating is formed.
There are many advantages to using combustion wire metallizing as a thermal spraying process. Combustion wire metallizing is one of the more affordable thermal spraying processes. Since an oxygen and fuel gas mixture is used as the source of heat, no large, expensive power sources need to be purchased and it is very portable.
This is advantageous for jobs that require coatings to be applied in remote or difficult to reach areas. The combustion wire metallizing process also allows the base material to stay relatively cool. This means that the base material will not be altered other than at its surface.