Issued October 2000 Supersedes January 1997

TM

Metco Aluminum Wire

Technical Bulletin #10-631

Metco Aluminum Wire

Electric Arc Wire for Protection Against Corrosion
Metco Aluminum is an excellent electric arc wire for applications requiring protection against atmospheric, chemical and heat corrosion. Metco Aluminum coatings provide anodic type protection to many types of materials including iron and cadmium. Therefore, the Metco Aluminum coating offers corrosion protection by sacrificial means and coating properties such as porosity and density are not of critical importance. However, use of a sealer is recommended in applications that require long or severe service conditions.

Table of Contents
Applications Typical Wire Properties Typical Coating Characteristics SmartArcTM (200 amps), 14 ga. Typical Coating Characteristics SmartArc (300 amps), 14 ga. Typical Coating Characteristics SmartArc (200 amps), 11 ga. Typical Coating Characteristics SmartArc (350 amps), 11 ga. Coating PhotoMicrographs SmartArc (50x) Recommended Finishing Procedures Safety Recommendations Storage Requirements Recommended Parameters SmartArc (200 amps), 14 ga. Recommended Parameters SmartArc (300 amps), 14 ga. Recommended Parameters SmartArc (200 amps), 11 ga. Recommended Parameters SmartArc (350 amps), 11 ga. page 3 page 3 page 3 page 4 page 5 page 6 page 7 page 7 page 8 page 8 page 8 page 9 page 10 page 11

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Metco Aluminum Wire

Applications
Metco Aluminum coatings are recommended for use in the following applications / environments: Corrosion Protection Electrical and Thermal Conductivity Reflective Coating Restoration of Dimension

Metco Aluminum is in conformance with Department of Defense Specification MIL-W-6712, Table II, Aluminum.

Typical Wire Properties

Typical chemical composition (weight %) of Metco Aluminum is as follows: Aluminum: 99.0 min

Wire diameter size available: 14 ga. (1.63 mm, 0.064 inches) and 11 ga. (2.31 mm, 0.091 inches)

Typical Coating Characteristics SmartArc (200 amps), 14 ga.

Air Cap: Primary Air Pressure, psi: Secondary Air Pressure, psi: Surface Profile: As-Sprayed, micrometers Ra: microinches aa: Hardness: Superficial hardness, Rh: Bond Strength (ASTM C-633)1: C Grit Blasted Steel, MPa: Psi: Density, g/cm3: Coating Thickness Limits: C Grit Blasted Steel, mm: 0.001 inches:
#10-631

Fine 35 0

Fine 60 0

Fan 35 20

Hi-Velocity 35 0

22 - 28 850 - 1100

14 - 18 550 - 700

20 - 28 800 - 1100

17 - 24 650 - 950

50 - 55

60 - 65

60 - 65

60 - 65

>34.2 >5,000 2.3

>34.2 >5,000 2.3

>34.2 >5,000 2.3

>34.2 >5,000 2.3

>5.1 >200

>5.1 >200

>5.1 >200

>5.1 >200
3

Metco Aluminum Wire

Typical Coating Characteristics SmartArc (200 amps), 14 ga. (contd)

Coating Weight: kg/m2/0.1mm: lb/ft2/0.001:

0.23 0.01

0.23 0.01

0.23 0.01

0.23 0.01

Typical Coating Characteristics SmartArc (300 amps), 14 ga.

Air Cap: Primary Air Pressure, psi: Secondary Air Pressure, psi: Surface Profile: As-Sprayed, micrometers Ra: microinches aa: Hardness: Superficial hardness, Rh: Bond Strength (ASTM C-633)1: C Grit Blasted Steel, MPa: Psi: Density, g/cm3: Coating Thickness Limits: C Grit Blasted Steel, mm: 0.001inches: Coating Weight: kg/m2/0.1mm: lb/ft2/0.001: Fine 35 0 Fine 60 0

23 - 30 900 - 1200

17 - 19 650 - 750

55 - 60

65 - 70

>34.2 >5,000 2.3

>34.2 >5,000 2.3

>5.1 >200

>5.1 >200

0.23 0.01

0.23 0.01

Bond strength measured using Master Bond EP15 epoxy from Master Bond, Inc., Hackensack, NJ. Results may vary depending on the curing process and type of epoxy used to perform the bond test.
1

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Metco Aluminum Wire

Typical Coating Characteristics SmartArc (200 amps), 11 ga.

Air Cap: Primary Air Pressure, psi: Secondary Air Pressure, psi: Surface Profile: As-Sprayed, micrometers Ra: microinches aa: Hardness: Superficial hardness, Rh: Bond Strength (ASTM C-633)1: C Grit Blasted Steel, MPa: Psi: Density, g/cm3: Coating Thickness Limits: C Grit Blasted Steel, mm: 0.001inches: Coating Weight: kg/m2/0.1mm: lb/ft2/0.001: Fine 35 0 Fan 25 20

20 - 28 800 - 1100

19 - 25 750 - 1000

45 - 50

35 - 40

>34.2 >5,000 2.3

>34.2 >5,000 2.3

>5.1 >200

>5.1 >200

0.23 0.01

0.23 0.01

Bond strength measured using Master Bond EP15 epoxy from Master Bond, Inc., Hackensack, NJ. Results may vary depending on the curing process and type of epoxy used to perform the bond test.
1

#10-631

Metco Aluminum Wire

Typical Coating Characteristics SmartArc (350 amps), 11 ga.

Air Cap: Primary Air Pressure, psi: Secondary Air Pressure, psi: Surface Profile: As-Sprayed, micrometers Ra: microinches aa: Hardness: Superficial hardness, Rh: Bond Strength (ASTM C-633)1: C Grit Blasted Steel, MPa: Psi: Density, g/cm3: Coating Thickness Limits: C Grit Blasted Steel, mm: 0.001inches: Coating Weight: kg/m2/0.1mm: lb/ft2/0.001: Fine 35 0

23 - 38 900 - 1500

35 - 40

>34.2 >5,000 2.3

>5.1 >200

0.23 0.01

Bond strength measured using Master Bond EP15 epoxy from Master Bond, Inc., Hackensack, NJ. Results may vary depending on the curing process and type of epoxy used to perform the bond test.
1

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Metco Aluminum Wire

Coating PhotoMicrographs SmartArc (x50)

200m Fig. 1 - SmartArc sprayed Aluminum with Fine Air Cap at 2.4 bar (35 psi).

200m Fig. 2 - Metco Aluminum coatings sprayed with Fan Air Cap at 2.4 bar (35 psi) (primary) and 1.4 bar (20 psi) (secondary) air pressure offer wider spray patterns.

200m Fig. 3 - Metco Aluminum coatings produced with a High Velocity Air Cap at 2.4 bar (35 psi).

Recommended Finishing Procedures

The recommended machining parameters for optimal coating are as follows: Tool Bit: Work Speed: Traverse Rate: Infeed: Lubricant: Kennametal K6 or equivalent 30 - 38 m/min. (100 - 125 SFPM) 0.076 mm/rev. (0.003 in./rev.) 0.076 mm/pass (0.003 in./pass) none

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Metco Aluminum Wire

Safety Recommendations
The Material Safety Data Sheet (MSDS) for Metco Aluminum Wire is available upon request. If personnel must be in the spray environment during spray operations, protective clothing, respirators, safety eyeglasses and ear protection must be worn. The spray area must always be equipped with suitable exhaust and dust collection systems.

Storage Requirements
Wires should be stored in a clean, dry area and preferably kept boxed in a carton.

Recommended Parameters SmartArc (200 amps), 14 ga.

Air Cap: Air Pressure: Primary, bar: psi: Secondary, bar: psi: Operating Parameters: Voltage, (V): Amperage, (A): Hourly Consumption: kg. Wire: lbs. Wire: Spray Distance: mm: inches: Wire Clamping Pressure: bar: psi: Front Roller Type: Deposit Efficiency, %: Wire Required: kg/m2/0.1mm: lb/ft2/0.001: Coverage: m2/hr/0.1mm ft2/hr/0.001:
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Fine

Fan

Hi-Velocity

2.4 - 4.1 35 - 60 0 0

2.4 35 1.4 20

2.4 35 0 0

26 - 28 200

26 - 28 200

26 - 28 200

4.5 10

4.5 10

4.5 10

127 - 178 5-7

127 - 178 5-7

127 - 178 5-7

1.0 - 1.4 15 - 20 Serrated 55

1.0 - 1.4 15 - 20 Serrated 50

1.0 - 1.4 15 - 20 Serrated 55

0.418 0.022

0.460 0.024

0.418 0.022

10.86 459.59
Metco Aluminum Wire

9.87 417.81

10.86 459.59
8

Recommended Parameters SmartArc (300 amps), 14 ga.

Air Cap: Air Pressure: Primary, bar: psi: Secondary, bar: psi: Operating Parameters: Voltage, (V): Amperage, (A): Hourly Consumption: kg. Wire: lbs. Wire: Spray Distance: mm: inches: Wire Clamping Pressure: bar: psi: Front Roller Type: Deposit Efficiency, %: Wire Required: kg/m2/0.1mm: lb/ft2/0.001: Coverage: m2/hr/0.1mm: ft2/hr/0.001: Fine

2.4 - 4.1 35 - 60 0 0

26 - 28 300

7.3 16

127 - 178 5-7

1.0 - 1.4 15 - 20 Serrated 55

0.418 0.022

17.37 735.34

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Metco Aluminum Wire

Recommended Parameters SmartArc (200 amps), 11 ga.

Air Cap: Air Pressure: Primary, bar: psi: Secondary, bar: psi: Operating Parameters: Voltage, (V): Amperage, (A): Hourly Consumption: kg. Wire: lbs. Wire: Spray Distance: mm: inches: Wire Clamping Pressure: bar: psi: Front Roller Type: Deposit Efficiency, %: Wire Required: kg/m2/0.1mm: lb/ft2/0.001: Coverage: m2/hr/0.1mm ft2/hr/0.001: Fine Fan

2.4 35 0 0

1.7 25 1.4 20

34 - 36 200

34 - 36 200

5.0 11

5.0 11

127 - 178 5-7

127 - 178 5-7

1.0 - 1.4 15 - 20 Serrated 65

1.0 - 1.4 15 - 20 Serrated 60

0.354 0.018

0.383 0.020

14.11 597.46

13.03 551.50

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Metco Aluminum Wire

10

Recommended Parameters SmartArc (350 amps), 11 ga.

Air Cap: Air Pressure: Primary, bar: psi: Secondary, bar: psi: Operating Parameters: Voltage, (V): Amperage, (A): Hourly Consumption: kg. Wire: lbs. Wire: Spray Distance: mm: inches: Wire Clamping Pressure: bar: psi: Front Roller Type: Deposit Efficiency, %: Wire Required: kg/m2/0.1mm: lb/ft2/0.001: Coverage: m2/hr/0.1mm: ft2/hr/0.001: Fine

2.1 30 0 0

34 - 36 350

8.6 19

127 - 178 5-7

1.0 - 1.4 15 - 20 Serrated 65

0.354 0.018

24.38 1031.98

The information provided in this document is for the convenience of Sulzer Metcos customers for the purpose of evaluation and proper use of the Sulzer Metco product(s) described herein. This document and the information contained herein is the property of Sulzer Metco and shall not be used, disclosed, or reproduced in whole or in part for any purpose other than for the use of said product(s). Nor shall this information be used in any way with goods not manufactured and sold by Sulzer Metco. Sulzer Metco makes no warranties, express or implied, as to the information contained herein.

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Metco Aluminum Wire

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