Our combustion wire spray services include anti-corrosion coatings and dimensional surface restoration. Metal-based wires are used in-shop or on-site for coating large steel structures, chemical and petroleum tanks, and marine applications.

Process description

We continually feed the spray material in wire form into a fuel gas-oxygen flame where it is melted by the heat of that combustion. Compressed air surrounds the flame and atomizes the molten tip of the wire. This accelerates the spray of molten particles towards the prepared workpiece surface. Combustion wire spray is a common choice for machine element repair and corrosion coatings. You have the option of either hard (higher melt temperature) or soft (lower melt temperature) wires.

Common Alloys 

  • Stainless Steel
  • Aluminum
  • Babbitt
  • Copper
  • Bronze
  • Chromium/Nickel

Process basics

Heat source Fuel and Oxygen
Material Wire (Metal)
Flame temperature Approx. 3,100 °C
Particle velocity Up to 200 m/s
Spray performance 15 – 1,400 g/min

Schematic diagram of a combustion wire process.

Key characteristics

  • Portable for on-site coatings
  • High spray rates with low gas consumption
  • Capable of spraying machinable alloys

Typical applications

  • Repair worn bearing areas
  • Restore damage faces
  • build up damage/worn rollers