Wire flame spraying process uses metals and alloys in wire form as its spraying materials, and combustion flame or electric arc as its heat source. The molten materials are sprayed onto the surface of the subject to form the coating. All metals and alloys in wire form are available for the material, such as copper, bronze, stainless steel, high carbon steel, molybdenum and low melting point metals including aluminum, Zinc and others.

Characteristics of wire flame spray process

The subjects to be sprayed are not affected by high temperature, which keeps the dimensional stability and morphological stability, causes no cracks, no strength reduction.

The coating with broad range of its thickness is available.

The coating contains harder particles than those of original materials and hard ingredients including metal oxide, nitride, carbide and etc., which provide high level of wearing resistance.


This process is basically the spraying of molten material onto a surface to provide a coating. Material in powder form is melted in a flame (oxy-acetylene or hydrogen most common) to form a fine spray. When the spray contacts the prepared surface of a substrate material, the fine molten droplets rapidly solidify forming a coating. This flame spray process carried out correctly is called a "cold process" (relative to the substrate material being coated) as the substrate temperature can be kept low during processing avoiding damage, metallurgical changes and distortion to the substrate material.

The main advantage of this flame spray process over the similar Combustion wire spray process is that a much wider range of materials can be easily processed into powder form giving a larger choice of coatings. The flame spray process is only limited by materials with higher melting temperatures than the flame can provide or if the material decomposes on heating.