Ni80Al20 Thermal Spray Wire for High-Temperature Corrosion Part Protection

Product Information

The Ni80Al20 spray wire is a high-performance alloy wire primarily designed for thermal spray coating applications. It consists of 80% nickel (Ni) and 20% aluminum (Al), offering a unique combination of properties ideal for creating durable, wear-resistant, and corrosion-resistant coatings on various industrial components. This wire is commonly used in harsh environments, including high-temperature conditions, where protection against corrosion, wear, and oxidation is essential.

Alternate Names:

• Nickel-Aluminum Spray Wire

• Ni-Al Coating Wire

• Ni80Al20  Thermal Spray Wire

• Nickel Aluminum Alloy Wire

Material Composition:

• Ni (Nickel): 80%

• Al (Aluminum): 20%

Appearance / Color:

• The wire has a silver-gray appearance with a shiny finish.

Wire Diameter:

• Available in a variety of diameters, including 1.6mm, 2.0mm, 2.5mm, and 3.0mm (custom sizes available upon request).

Flux Coating:

• No flux coating is needed as the wire is designed to melt and deposit directly onto the substrate during the thermal spraying process.

Key Features & Properties:

• Excellent Wear Resistance: The alloy's composition provides outstanding resistance to abrasion and wear, making it ideal for coatings on components subjected to heavy friction.

• Superior Corrosion Resistance: Ni80Al20 has excellent resistance to oxidation and corrosion, particularly in high-temperature environments, which is beneficial for parts exposed to harsh chemicals or high moisture.

• High Temperature Stability: The alloy performs well in elevated temperature conditions, protecting parts from thermal degradation and oxidation in applications such as gas turbines and heat exchangers.

• Enhanced Bonding Strength: The wire promotes strong adhesion to a wide variety of substrates, providing long-lasting protective coatings that improve the lifespan of industrial components.

• Good Metallurgical Properties: Ni80Al20 can form a stable, dense, and uniform coating with a minimal risk of cracking or delamination.

Technology

Ni80Al20 is designed for thermal spray techniques, where it is melted by heat and propelled onto the surface of the workpiece. As the spray material cools, it forms a strong, adherent coating that provides excellent protection against wear and corrosion.

• Thermal Spray Methods: Suitable for flame spraying, arc spraying, and plasma spraying.

• Spray Coating Properties: Once applied, the Ni80Al20 alloy forms a protective oxide layer on the surface, preventing further oxidation and enhancing wear resistance.

• Melting Point: The alloy melts at a relatively low temperature compared to many other high-performance alloys, facilitating easier spraying.

Theory

The alloy works by creating a durable coating that adheres to the surface of the substrate. When heated to its melting point, the wire is sprayed onto the substrate, and upon cooling, it forms a dense, uniform layer. The alloy’s high content of nickel and aluminum promotes the formation of aluminum oxide on the surface of the coated component, which improves its oxidation resistance and wear resistance.

Applications:

• Aerospace: Ideal for coating turbine blades, engines, and other high-temperature components to enhance their durability and protect them from oxidation.

• Automotive: Used for protecting engine parts, exhaust systems, and other components exposed to extreme conditions.

• Power Generation: Excellent for coating parts in steam and gas turbines, heat exchangers, and other equipment exposed to high heat and wear.

• Marine Industry: Coating for parts exposed to seawater and corrosive environments, including propellers, engine parts, and other components.

• Heavy Machinery: Coating for components in mining, construction, and industrial equipment that are subjected to wear, corrosion, and high temperatures.

Usage Instructions:

• Preparation: Ensure the surface to be coated is clean and free from contaminants such as oil, rust, or dirt. The substrate should be preheated if necessary to enhance coating adhesion.

• Spraying Process: Use an appropriate thermal spray system (such as flame spray, arc spray, or plasma spray) to melt the wire and deposit it onto the surface. Ensure the spray parameters are optimized for the material and part size.

• Post-Coating: After applying the coating, allow the surface to cool down gradually. Depending on the application, the coating may be subject to further treatments like grinding or polishing to achieve the desired surface finish.

Size and Packaging

Wire Diameter:

• Available in 1.6mm, 2.0mm, 2.5mm, and 3.0mm (custom diameters available upon request).

Packaging:

• Typically available in 5 kg sealed boxes for convenient handling and storage.

Advantages:

1. Improved Component Longevity: By applying Ni80Al20 coatings, the lifespan of components subjected to extreme conditions is significantly increased, reducing the frequency of replacements and maintenance.

2. Cost-Effective Solution: Reduces the need for expensive materials and treatments by enhancing the performance of existing parts through surface modification.

3. High Resistance to Oxidation: The aluminum content ensures excellent resistance to oxidation at high temperatures, making it perfect for components exposed to heat and atmospheric elements.

4. Versatile Application: Compatible with a variety of substrates, including steel, alloys, and other metals, making it a versatile solution for various industries.

5. Superior Coating Uniformity: The wire allows for smooth and uniform coatings, reducing the risk of defects and improving the overall performance of the part.

Parameters Table / Selection Table