WIRES

THERMAL SPRAY CONSUMABLES GUIDE

 Wires

Index

Cross Reference List (chemistry only) ––––––––––––––––––––––––––––––––––––––––––– 30
Pure Zinc––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 29
Zinc – Aluminum –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 29
Pure Aluminum –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 29
Alloy C-276 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 29
NiCrTi ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 29
Alloy 625 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 29
NiCrAl –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 30
NiAlMo –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 30
NiAl 95/5 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 30
NiAl 80/20 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 30
NiCr 80/20 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 30
NiCr 80/20 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 30
Molybdenum ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 31
Stainless Steel 420 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 31
Stainless Steel 316L ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 31
Stainless Steel 307 –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 31
1.0%C-Steel –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 31
Ni-base WC––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 32
Alloy 88 –––––––––––––––––––––––––––––––––––––––––––––––––––– 32
Ni S/F Alloy + W–––––––––––––––––––––––––––––––––––––––––––––– 32
NiCr 30 Ceramic–––––––––––––––––––––––––––––––––––––––––––––– 32
FeCrMnSiB –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 33
Fe-Base CrC –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 33
Fe-Base WC –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 34
NiCrAlY –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 34
Pure Copper ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 34
CuAl ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 34
Monel –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 34
Alloy 6 –––––––––––––––––––––––––––––––––––––––––––––––––––––– 35
Alloy 12 ––––––––––––––––––––––––––––––––––––––––––––––––––––– 35
Alloy T-400 ––––––––––––––––––––––––––––––––––––––––––––––––– 35
Babbitt ––––––––––––––––––––––––––––––––––––––––––––––––––––– 35

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Wires

CROSS REFERENCE LIST (chemistry only)

Wire Type FST p/n TAFA/PX Sulzer Metco Page Nr.
Pure Aluminum W-200 01T Aluminum 31
Alloy C-276 W-322 77T 8276 31
NiCrTi W-345 45CT 8452 31
Alloy 625 W-365 71T 8625 31
NiCrAlY W-372 76MXC – 31
NiCrAl W-373 73MXC 8443 32
NiAlMo W-374 74MXC 8447 32
NiAl 95/5 W-375 75B 8400 32
NiAl 80/20 W-377 – 405 32
NiCr 80/20 W-385 06C 8450 32
Molybdenum W-400 13T Sprabond 32
Stainless Steel 420 W-504 60T 2 33
Stainless Steel 316L W-510 88T 4 33
Stainless Steel 307 W-515 55T 5 33
High C-Steel W-550 38T Sprasteel 80 33
Low C-Steel W-555 30T Metco 8230 33
Ni-Base WC W-610 – – 33
FeCrSiB W-662 95MXC – 35
FeCrSiB W-663 90MXC – 35
FeCrSiB W-664 96MXC – 35
FeCrSiB W-665 98MXC – 35
FeCrSiB W-667 97MXC – 36
Pure Copper W-700 05T Copper 36
CuAl W-710 10T Sprabronze 36
CuAlFe W-712 Spraybronze 36
Monel W-717 70T Monel 36
Stellite 6 Equivalent W-856 – – 36
Stellite 12 Equivalent W-866 – – 37
T400 Equivalent W-850 – – 37
Babbitt W-970 – Sprababbitt 37

30 | THERMAL SPRAY WIRES 2020

The information contained in this document is offered as a guide only. It does not form any
part of any sales contract as guaranteed performance of the delivered product. References
to equivalent products are for guidance only.
 Wires

WIRES
Wire Type Composition FST p/n Diameter (mm) Typical Properties and Applications

Pure Aluminum Al > 99.0% W-200.1 1.6 mm (1/16”) • Coatings are resistant to
atmospheric, chemical and heat
AW1350 W-200.3 3.2 mm (1/8”) corrosion
• Electrical and heat conductive.

AW1100 W-201.1 1.6 mm (1/16”

W-201.3 3.2mm (1/8”)

Alloy C-276 Ni Bal. W-322.1 1.6 mm (1/16”) • Excellent high temperature

Cr 15.0% oxidation and corrosion
Fe 5.0% properties
Mo 16.0% • Good for repair and build-up
W 4.0% of similar chemistry super alloy
components.

NiCrTi Cr 45.0% W-345.1 1.6 mm (1/16”) • Specially designed for Boiler

Ti 1.0% applications
Ni Bal. • Titanium pre-alloyed, resulting in
superior bondstrengths
• W-345.1 produces coatings
which are extremely resistant to
corrosive vanadium and sulfur
gases in boiler atmospheres.

Alloy 625 Ni Bal. W-365.1 1.6 mm (1/16”) • Excellent high temperature

Cr 22.0% oxidation and corrosion properties
Fe 2.0% • Good for repair and build-up
Mo 9.0% of similar chemistry super alloy
Nb/Ta 3.5% components
• Useful up to 980ºC (1800ºF)

NiCrAl Cr 20.0% W-373.1 1.6 mm (1/16”) • Resistant to oxidation and

Al 7.0% corrosion at high temperature
Ni Bal. • Undercoat for ceramics topcoat
• Recommended for salvage and
Cored Wire build-up of mis-machined or
worn machine parts.

Inconel is a registered trade mark of Inco.

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Wires

WIRES
Wire Type Composition FST p/n Diameter (mm) Typical Properties and Applications

NiAlMo Mo 5.0% W-374.1 1.6 mm (1/16”) • Recommended for salvage and

Al 5.5% build-up of both machinable and
Ni Bal. grindable carbon steels
• Good resistance against wear and
Cored Wire particles
• Used for high strength and low
shrink coatings.

NiAl 95/5 Al 5.0% W-375.1 1.6 mm (1/16”) • Excellent bonding

Ni 95.0% • Oxidation and abrasion resistant
at elevated temperatures
• Self bonding material.
• Suitable for dimensional
restoration.

NiAl 80/20 Al 20.0% W-377.3 3.2 mm (1/8”) • Self bonding material.

Ni 80.0% • Coatings are dense, resistant to
oxidation and high temperature
Cored Wire and temperatures changes
• Mainly used for Flame Wire
Spraying.

NiCr 80/20 Ni 80.0% W-385.1 1.6 mm (1/16”) • Produces coatings which resist
Cr 20.0% corrosive gasses and oxidation
temperatures up to 980ºC
Cored Wire (1800ºF)
• Used as bond coat for ceramic
materials
• Coatings are machinable.

NiCrAlY Ni Bal. W-372.1 1.6 mm (1/16”) • Resistant to oxidation and

Cr 19.5% corrosion at high temperature
Al 10,5% • Undercoat for ceramics topcoat
Y 0,8% • Recommended for salvage and
build-up of mis-machined or
worn machine parts.

Molybdenum Mo 99.9% W-400.3 3.2 mm (1/8”) • Galling and Scuffing resistance

• Typical applications include
synchroniser rings, selector forks
and piston rings.

32 | THERMAL SPRAY WIRES 2020

The information contained in this document is offered as a guide only. It does not form any
part of any sales contract as guaranteed performance of the delivered product. References
to equivalent products are for guidance only.
 Wires

WIRES
Wire Type Composition FST p/n Diameter (mm) Typical Properties and Applications

Stainless Steel 420 13% Cr-Steel W-504.1 1.6 mm (1/16”) • The best all purpose material for
general engineering applications
W-504.3 3.2 mm (1/8”) • Excellent wear properties and
fair corrosion resistance
• Typically used for reclamation
• Low shrinkage, allows for thick
build-up.

Stainless Steel Cr 17.5% W-510.1 1.6 mm (1/16”) • Type 316L Austenitic Stainless
316L Ni 12.0% Steel
Mo 2.2% W-510.3 3.2 mm (1/8”) • Good corrosion resistance
C <0,08% • Dimensional restoration.

Stainless Steel 307 Cr 18.5% W-515.1 1.6 mm (1/16”) • Type 307 Austenitic Stainless
Ni 8.5% Steel
Mn 6.5% W-515.3 3.2 mm (1/8”) • Good corrosion resistance
C <0,12% • Dimensional restoration.

High C-Steel Si 0.20% W-550.1 1.6 mm (1/16”) • Can be used wherever hard, low
C 0,80% shrink steel is required
Mn 0,65% W-550.3 3.2 mm (1/8”) • Poor corrosion resistance
Fe Bal. • Dimensional restoration.

Low C-Steel Si 0.12% W-555.1 1.6 mm (1/16”) • Can be used wherever low shrink
C <0,15% steel is required
Mn 1,10% W-555.3 3.2 mm (1/8”) • Poor corrosion resistance
Fe Bal. • Dimensional restoration.

Ni-WC Ni Bal W-610.1 1.6mm (1/16”) • Nickel Silicon Boron based Wire
Ni-Hardcore™ Si 5.0% with >50% Fused Tungsten
B 2.0% Carbide (FTC). The coating
C 0,7% results in a hard nickel backed
WC >50% matrix (540 HV0,1) with hard FTC
particles (2400 HV0.1). Wire is
typically for application where
a high abrasion resistance is
required up to a temperature of
500°C.

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Wires

WIRES
Wire Type Composition FST p/n Diameter (mm) Typical Properties and Applications

NiCrSiBW Ni Bal. W-612.1 1.6mm (1/16”) • Wire equivalent to Colmonoy® 88.

Ni-Hardcore™ Si 3.0% • W-612 is a hard surfacing alloy.
B 2.8% This alloy consists of NiCrSiBFe
Cr 16.0% and WC. The combination of
W 15.0% complex borides and carbide
with the Ni-Cr-B matrix offers
excellent hardness (500-600
HV0.3)) and extends the service
life of parts exposed to high
temperature abrasion, erosion,
corrosion, galling and fretting.

NiCrW Ni Bal. W-614.1 1.6mm (1/16”) • Very similar material to W-612,

Ni-Hardcore™ Si 2.5% but due to it higher content
B 2.7% of WC has a higher hardness
Cr 24.0% (800-900 HV0.3) and is typically
W 22.0% used for the toughest abrasion
applications.

Ni-Ceramic Ni Bal. W-615.1 1.6 mm (1/16”) • W-615 is a unique ceramic filled

ZrO2Al2O3Cr2O3 cored wire. A customized oxide
30% blend had been developed
for optimum wear resistance.
Good oxidation and corrosion
resistance and withstand hot
erosion. It is recommend to use
W-372 a NiCrAlY cored wire a
bond coat. A typical Application:
Cooling panels of fume
extraction units of electric arc
furnaces

NiCrSiBW Ni Bal. W-618.1 1.6 mm (1/16’’) • A NiCrBSi cored wire used for
Ni-Hardcore™ Si 4.5% wear resistant and corrosion
B 1.6% resistant protective coatings.
Cr 20.0% Coatings can be fused after
W 2.0% application (self-fluxing). They
Fe-Hardcore™ is a Trade name of Praxair reach hardness of 500 - 800
HV0,1 and show porosity of
below 2%. The coatings can
be machined by grinding and
polishing. Made exclusively for
arc spraying, W-618 is used for
high loaded components of
chemical plants or food industry,
plunger.

34 | THERMAL SPRAY WIRES 2020

The information contained in this document is offered as a guide only. It does not form any
part of any sales contract as guaranteed performance of the delivered product. References
to equivalent products are for guidance only.
 Wires

WIRES
Wire Type Composition FST p/n Diameter (mm) Typical Properties and Applications

FeCrMnSiB Cr 26.0% W-662.1 1.6 mm (1/16”) • Hardness approx 55 HRC

Fe-Hardcore™ Si 1.5% • Equivalent to 95MXC(*)
Mn 1.6% • Produces a hard, abrasive and
B 3.3% corrosion resistant coating
C 0.25 % • Material has unique feature to
Fe Bal. increase hardness while in service
• Conventional machining provide
Cored Wire hard chrome like finish
• Low coefficient of friction.

FeCrMnSiB Ni 9.0% W-663.1 1.6 mm (1/16”) • Hardness approx 45 HRC

Fe-Hardcore™ Cr 23.0% • Equivalent to 90MXC(*)
Mo 4.0% • Produces a hard, abrasive and
Si 1.0% corrosion resistant coating
Mn 1.3% • Material has unique feature to
Cu 2.0% increase hardness while in service
B 2.3% • Conventional machining provide
Fe Bal. hard chrome like finish
• Low coefficient of friction.

FeCrMnSiB Ni 8.0% W-664.1 1.6 mm (1/16”) • Hardness approx 50 HRC

Fe-Hardcore™ Cr 21.0% • Equivalent to 96MXC(*)
Mo 3.2% • Good abrasive and corrosion
Si 1.1% resistant coating at high
Mn 1.2% temperature
Cu 2.0% • Material has unique feature to
B 2.3% increase hardness while in service
Fe Bal. • Low coefficient of friction.

Cored Wire

Fe-Base CrC Fe- Ni 3.0% W-665.1 • Hardness approx 40 HRC

Hardcore™ Cr 26.0% • Equivalent to 98MXC(*)
Mo 0.8% • Produces a hard, abrasive and
Si 1.6% corrosion resistant coating
Mn 1.6% • Material has unique feature to
C 1.7% increase hardness while in service
Fe Bal. • Conventional machining provide
hard chrome like finish
Cored Wire • Low coefficient of friction.

Fe-Hardcore™ is a Trade name of Praxair

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Wires

WIRES
Wire Type Composition FST p/n Diameter (mm) Typical Properties and Applications

Fe-Base WC Fe- Ni 4.5% W-667.1 1.6 mm (1/16”) • Hardness approx 65 HRC

Hardcore™ Cr 14.0% • Equivalent to 97MXC(*)
Si 1.3% • Excellent abrasion resistance
Mn 0.6% • Typical applications include:
B 1.9% mining equipment, pump
TiC 6.0% equipment etc.
WC 26.0%
Fe Bal.

Cored Wire

Pure Copper Cu 99.9% W-700.1 1.6 mm (1/16”) • Used for electrical conductivity
applications, copper reclamation
W-700.3 3.2 mm (1/8”) and decorative coatings.

CuAl Al 10.0% W-710.1 1.6 mm (1/16”) • Produces dense, wear resistant

Cu Bal. coatings which are very
W-710.3 3.2 mm (1/8”) machinable.

CuAlFe Al 9.0% W-712.1 1.6 mm (1/16”) • Produces dense, wear resistant

Fe 1.0% coatings which are very
Cu Bal. W-712.3 3.2 mm (1/8”) machinable.

Monel Cu 30.0% W-717.1 1.6 mm (1/16”) • Used for corrosion protection

Ni Bal. against brine or lye solutions;.
W-717.3 3.2 mm (1/8”) however should not be used in
acidic environments.
• Marine corrosion protection
• Excellent finishing.

Alloy 6 C 0,95% W-856.1 1.6 mm (1/16”) • Equivalent to Alloy 6

Co-Hardcore™ Si 1.4% • To be used when excellent
Mn 0.8% resistance to metal to metal
Cr 30% wear, oxidation,. High
Fe 3.0% temperatures and corrosive
W 4.20% environments
Co Bal. • Valves in power industry
• Forging and mixing tools
• Risers

Fe-Hardcore™ is a Trade name of Praxair

36 | THERMAL SPRAY WIRES 2020

The information contained in this document is offered as a guide only. It does not form any
part of any sales contract as guaranteed performance of the delivered product. References
to equivalent products are for guidance only.
 Wires

WIRES
Wire Type Composition FST p/n Diameter (mm) Typical Properties and Applications

Alloy 12 C 1.15% W-866.1 1.6 mm (1/16”) • Equivalent to Alloy 12

Co-Hardcore™ Si 1.8% • To be used when excellent
Mn 0.9% resistance to metal to metal
Cr 29% wear, oxidation,. High
Fe 3.0% temperatures and corrosive
W 6.50% environments
Co Bal. • Valves in power industry
• Forging and mixing tools
• Risers

Alloy T-400 Mo 28.0% W-850.1 1.6 mm (1/16”) • Excellent sliding wear properties
Co-Hardcore™ Cr 8.0% up to 800 C
Si 2.0% • Good hardness, oxidation and
Fe 3.0% corrosion properties
Co Bal. • Low coefficient of friction
• Suitable for applications with low
lubrication
• Similar to Triballoy 400

Babbitt Sb 7.5% W-970.2 2.0 mm • Produces dense coatings which

Cu 3.5% are suitable for high speed and
Sn Bal. W-970.3 3.2 mm (1/8”) heavy duty bearings
• Bearing reclamation.

NOTE: in this Consumable Guide the most generally industrial used wire products
are listed. If products other than listed in this catalogue are required, please contact
our customer support team.

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Notes

39 2020
 Masking

Index

Masking Tapes ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 39
Masking Compound ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 41
Others & Approvals –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 41

MASKING TAPES
FST p/n Size Range Applications Description

DW 500-10.0 10.0 mm x 33 m Plasma Tape • DW 500 is a one step plasma masking

tape constructed of a silicone rubber/glass
DW 500-12.5 12.5 mm x 33 m cloth backing coated with an aggressive
high-temperature silicone adhesive. It
DW 500-25.0 25.0 mm x 33 m will withstand grit blast and plasma spray
process yet will remove cleanly. DW 500
DW 500-38.0 38.0 mm x 33 m has a higher tack than most other plasma
masking tapes which allows it to easily
DW-500-50.0 50.0 mm x 33 m conform to the most complex shapes of the
Aircraft Industry.
• DW 500 & DW 500R (red color for
identification) plasma masking tape have a
CCS13 (Rolls-Royce) approval.

DW 501-10.0 10.0 mm x 16.5 m HVOF Tape • DW 501 is a laminate of blue silicone

rubber, glass fabric, 4 mil aluminum and
DW 501-12.5 12.5 mm x 16.5 m glass fabric designed for severe duty
including HVOF applications. The Silicone
DW 501-25.0 25.0 mm x 16.5 m adhesive will release cleanly.
• This tape is used as a masking tape
DW 501-38.0 38.0 mm x 16.5 m for HVOF spraying. The double-ply
construction provides superior protection
DW-501-50.0 50.0 mm x 16.5 m in this demanding high velocity spray
environment.

DW 411-10.0 10.0 mm x 33 m Plasma/HVOF • DW 411 is a heavy (4 mil) aluminum foil/

Tape glass laminate with a high temperature
DW 411-12.5 12.5 mm x 33 m silicone adhesive. The aluminum foil
provides excellent and conductive
DW 411-25.0 25.0 mm x 33 m characteristics in high temperature
applications. The silicone adhesive provides
DW 411-38.0 38.0 mm x 33 m excellent adhesion at high temperatures
yet will remove cleanly.
DW-411-50.0 50.0 mm x 33 m

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