OEM ODM ARC Thermal Spray Wire Ni80Al20 0.8mm 1.6mm MIG Chemical Processing

Product Description

Ni80Al20 Thermal Spray Wire is a high-performance Nickel-Aluminum alloy wire containing approximately 80% Nickel and 20% Aluminum by weight. It is specifically designed for thermal spraying applications such as flame spraying, electric arc spraying, and plasma spraying. This alloy wire is widely used to create bond coats or corrosion-resistant coatings on various substrates including carbon steel, stainless steel, and non-ferrous metals.

Also Known As:

• Nickel 80/20 Thermal Spray Wire

• NiAl Bond Coat Wire

• Arc Spray Ni80Al20 Wire

• Nickel Aluminum Thermal Spray Wire

Material Composition (Typical):

• Nickel (Ni): 79.5–80.5%

• Aluminum (Al): 19.5–20.5%

• Trace elements: <0.5%

Appearance / Color:

• Metallic silver-gray solid wire

• Supplied on spools or coils, clean and dry surface

Available Wire Diameters:

• 1.2 mm, 1.6 mm, 2.0 mm, 2.3 mm, 2.5 mm

• Custom diameters available upon request

Packaging:

• 15 kg spools / 20 kg coils / 25 kg drums

• Vacuum-packed or plastic-wrapped for moisture protection

Standard:

• Conforms to ASTM B833, AWS A5.21 NiAl

• Used in accordance with ISO 14919

Characteristics

• Excellent Adhesion: Forms strong bond coats on a wide range of substrates

• Good Corrosion Resistance: Particularly in oxidizing, marine, and mildly acidic environments

• High-Temperature Resistance: Stable at elevated temperatures, suitable for turbine and furnace coatings

• Conductive Coating Capabilities: Can be used as an electrical shielding or conductive layer

• Versatile Application Methods: Compatible with flame, arc, and plasma spray systems

Technology

The Ni80Al20 alloy wire is designed for thermal spray deposition. In flame or arc spray processes, the wire is fed into a spray gun, melted by a flame or electric arc, and atomized into fine droplets. These droplets are propelled by compressed air onto the surface of the substrate, where they flatten and solidify to form a dense, adherent coating.

In plasma spraying, higher temperatures and controlled atmospheres can produce coatings with improved microstructure and bonding characteristics.

Theory

The performance of Ni80Al20 stems from the synergistic properties of nickel and aluminum. Nickel provides excellent corrosion and oxidation resistance, while aluminum enhances bond strength and thermochemical reactivity with the substrate. During spraying, aluminum may oxidize slightly, aiding in mechanical interlocking and chemical bonding. The result is a versatile intermetallic layer that serves as either a bond coat or standalone protective coating.

Application / Usage

1. Bond Coats for Thermal Barrier Coating Systems:

• Acts as a base layer to improve adhesion for ceramic or high-temp coatings on turbine blades, exhaust ducts, and engines.

2. Corrosion Protection in Marine and Industrial Environments:

• Used on pipes, tanks, and structural steel exposed to saltwater, humidity, or aggressive industrial gases.

3. Dimensional Restoration and Wear Resistance:

• Rebuilds worn shafts, housings, and components with smooth, machinable surfaces.

4. Electrical Conductive Coatings:

• Applied on composite or plastic parts for EMI shielding or conductive pathways.

Selection Table / Parameters Table

Advantages / Selling Points

• Strong Bonding Performance: Ideal under ceramic top coats or as stand-alone layers

• High Versatility: Effective in diverse industries from aerospace to oil & gas

• Excellent Processability: Works smoothly in multiple spray systems with stable feed

• Oxidation & Heat Resistance: Extends lifespan of components in hot, aggressive environments

• Reliable Quality Control: Manufactured with precise composition and strict tolerances

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