Wire Flame Spray Gun

Wire Flame Spray Gun is the set of approaches in which an oxy-fuel flame melts the wires. After melting the melted metals are then atomized with compressed air to create a spray stream that applies the coating on the surface being sprayed. A flame Spray gun is used for spraying both ferrous & nonferrous material. Major applications are restoring worn-out components, conductivity, and anti-corrosion coating.

The wire is fed into the front torch of flame spray through the air-driven turbine. Fuel gas like acetylene, LPG, Propane & oxygen is properly and safely mixed in the siphon plug head assembly which provides a combustible heat source.

Normally, proper for all metals and metal alloys in wire form are used for spray coating i.e. Aluminum Brass, Bronze, Steel, Stainless Steel, Molybdenum wire, Nickel Alloy, Zinc, Copper, etc. General Wire is used for flame spray.

The Combustion Wire Thermal Spray Process is a coating process that involves spraying molten metal onto a surface. Material in the form of wire is melted in a flame (most commonly an oxy-acetylene flame) then atomized with compressed air to generate a thin spray. When the spray comes into contact with a substrate material's prepared surface, the thin molten droplets quickly solidify, forming a coating.

Characteristics of wire flame spraying process coatings

• High temperatures have no effect on the topics to be sprayed, ensuring dimensional and morphological stability, as well as the absence of cracks and strength reduction.
• Coatings with a wide range of thicknesses are available.
• The coating contains harder particles than the original materials, as well as hard ingredients such as metal oxide, nitride, carbide, and other hard elements that provide a high level of wear resistance.
• Anti-corrosion cathodic coatings on steel with zinc and aluminum.
• Bond coats and self-bonding coatings made of nickel/aluminum composite wire.
• Molybdenum for bond coats.
• Molybdenum for hard bearing applications, excellent resistance to adhesive wear, used on piston rings, synchromesh cones and journals.
• High Chromium steel for many applications requiring hard and wear resistant coating
• Bronzes, Babbitt for bearing applications
• Stainless Steels, Nickel and Monel for anti-corrosion and wear

Advantages for Wire Flame Spray Gun

• The cost of the Wire Flame spray system is less as compared to other thermal spray processes.
• Our Wire flame spray system is simple and easy to operate.
• The Wires are generally cheaper than powder.
• The process gives a high deposit efficiency.
• Possibly still best for applying pure molybdenum coatings for wear-resistant coatings.
• Shot Blaster’s wire flame spray system is portable and can be carried anywhere with ease.
• It is possible to use the system in areas without electricity supply. Only the compressor is electrically powered.
• Little operator training is necessary to use the equipment
• Flame spraying equipment is portable and suitable for manual use without the need for mechanized manipulators.

Types of Wire Flame Spray Gun

We provide various types of wire flame spray guns such as:

• 5KM Wire Flame Spray Gun- This gun has been created specifically for use in an automated, mass-production setting. It may be used for lengthy durations of continuous spraying without sacrificing coating quality. It's dependable and cost-effective, with the smallest amount of downtime possible.The gun is powered by a strong constant-speed motor that allows for accurate wire speed control. The powerful wire drive system ensures a continuous and smooth supply of wire material throughout the coating process thanks to its powerful variable speed motor. A speed control regulator is installed on the gun to allow for easy wire speed modulation. The gun comes with an external wire feed panel that indicates the wire speed. The 5KM gun can be maintained rapidly whenever it is needed, allowing it to return to production with minimal downtime.
• 11M Wire Flame Spray Gun- The gun is designed to run at a rapid rate, allowing the user to efficiently and affordably spray the appropriate soft wire material on the substrate. The wire feed thumb trigger makes this gun ideal for hand-held or start/stop operation. This gun was designed for soft-wire applications and will not spray hard materials such as Stainless Steel, Nickel, Bronze, Copper, or other metals. The 11M model is capable of handling both small jobs and large-area applications. It may spray soft metalizing wires of Lead, Aluminum Wire, Zinc Wire, Tin, and Babbitt with melting points of 1/8′′ (3.17mm), 5/12′′ (3.97mm), and 3/16′′ (4.76mm).

Various Air Cap, Nozzle, and Siphon plug configurations expand the versatility of the equipment, resulting in superior coating quality and cost-effective operation. Converting from one wire size to another is a straightforward and quick process. In very corrosive settings, the equipment is frequently used to coat or repair other metals. The gun can be used in hand-held, stationary, or mobile applications. For mobile applications and field repair work, the entire system (excluding the compressor) can be put on a cart.

• 12M Wire Flame Spray Gun- The 12M Wire Flame Spray Gun is a multi-purpose pistol that may be used to coat combustion flames with thermal spray wires. The conventional gun uses acetylene as the fuel gas to spray 1/8-inch wire. For additional sizes, appropriate hardware is available to handle all conventional wire sizes from 3/16" to 20 gauges.The 12M Wire Flame Spray Gun can spray wire at speeds ranging from 1.5 feet (457mm) per minute (with ordinary gears) to over 45 feet (13,716 mm) per minute (with the special, easily installable, high-speed gear set). The high-speed gear set is used to spray metals with lower melting points, such as Babbitt, Tin, and Zinc, at high speeds indefinitely. The gun can be used in hand-held, stationary, or mobile applications. For mobile applications and field repair work, the entire system (excluding the compressor) can be put on a cart.
• 14M Wire Flame Spray Gun- This is a small piece of equipment that draws wire in with an air turbine, melts it with fuel gas, and then blasts the molten particles onto the substrate. This versatile gun has a handy wire feed thumb trigger that makes it ideal for hand-held use. The Metal Coat Flame Spray Gun 14M is equipped with a universal gas head that may be used with either Oxy/Acetylene or Oxy/Propane fuel gas. Because of the fuel gas, a normal gun can spray roughly 1/8′′ wire with acetylene. On request, appropriate hardware for handling all typical wire sizes from 3/16′′ to 1/16′′ is available. With conventional gears, the flame spray torch's controlled speed ranges from about 2 to 15 feet per minute (0.6 – 4.6 m/min) to about 5 to 45 feet per minute (0.6 – 4.6 m/min).

Although the 14M Wire Flame Spray Equipment is primarily intended for hand-held use, a basic, durable tool post fixture may be included with the equipment to facilitate attachment on a machine tool such as a lathe.

• 11ED Electric Drive Wire Flame Spray Gun- The DC Motor of the 11ED Wire Flame Spray Gun was designed after years of experience and research in the thermal spray sector. This is the greatest gun in its class for spraying soft wires like aluminum, zinc, lead, tin, babbitt wire, and other metals.When compared to other wire flame spray models, this gun has the fewest parts and is the easiest to maintain. The Wire Flame Spray Gun's DC motor ensures a steady wire feed rate, resulting in improved coating quality.
• 12ED Electric Drive Wire Flame Spray Gun- The 12ED Wire Flame Spray Gun is the most advanced electric drive wire flame spray gun on the market. This variant includes an AC-powered motor that assures continuous wire feed rates and eliminates any speed variations that may occur with air-driven wire feeding. The continuous wire feed rate enables spraying hard wire like Molybdenum, Stainless Steel, Mild Steel, and other metals a breeze, resulting in great coatings. In comparison to other wire flame spray torches, the 12ED Model requires less maintenance.This model is designed to easily spray hard wires such as stainless steel and molybdenum. The most common wire size is 1/8′′. (3.17mm). It can also spray 11G, 15G, 1.6mm, 2mm, and 2.5mm wires.

Wire Flame spray gun system comprises the following

• Wire flame spray gun
• Gas Flow Meter
• Gas control unit
• Air control unit
• Wire reel stand
• Hose unit

Wire Flame Spray Equipment Manufacturer

We have been manufacturing wire flame spray equipment and coating systems for almost 20 years, therefore we are unquestionably specialists in the field. Air turbine-driven versions – 11M, 12M, and 14M Wire Flame Spray Equipment; and electric motor-driven models – 5KM, 11ED, and 12ED Wire Flame Spray Equipment – make up our wire flame spray equipment line. Wire flame spray systems are available in manual and automatic configurations. Although most Wire Flame spray systems are operated manually, we can semi-automate or entirely automate our systems if necessary. We also have a large stock of thermal spray spare parts on hand for our customers' emergency needs.

We also manufacture the Metal Spray Gun, Thermal Spray Gun, & Spare Parts.