Flame Spray
Flame spray is a process that uses an oxy-fuel flame to melt wires and in some cases powders or ceramic rods. The molten material is then atomised with compressed air to create a spray stream that applies the coating onto the surface being sprayed. Anti-corrosion coatings are typically applied with oxy-propane systems. Engineering coatings are typically applied with oxy-acetylene systems. Where propane is not available, oxy-acetylene systems can apply anti-corrosion coatings. Flame spray systems are commonly manually operated but it is possible to semi-automate or fully-automate the process if required.
Heat Source: Gas fuel* and oxygen flame (*commonly propane or acetylene)
Material: Wire or powder or ceramic rods
Transfer: Compressed air (wire flame)
Process: The gas fuel and oxygen are mixed and ignited to produce a flame. The material, either a wire or powder is fed into the flame. For wire flame spray, the material is melted and the compressed air, passing through a spray nozzle atomises the molten metal and sprays it onto the work piece. For powder flame spray, the powder particles (metal or ceramic) are softened in the flame and the speed of the flame gases through the nozzle sprays the softened powder onto the work piece.
MK73 WIRE FLAME
The Metallisation MK73-FS is an oxygen-propane fuelled flame spray system giving un-rivalled anti-corrosion coatings. The 'FS' stands for Free-Standing as the new control board can be free standing, wall mounted or fitted in a trolley.
The lightweight, well-balanced, robust pistol offers the quickest spray rates on the market, saving you both time and money. Systems can be supplied as continuous spray or, more commonly, with a unique stop/start function that allows the operator to stop spraying but keep the flame lit without damage to the pistol.
New in 2014 is a more ‘site friendly’ control panel. It is more robust and offers further protection to the flowmeter and ARF unit. It can be wall mounted or will free-stand on the floor. The flow of hoses is neater than the previous unit.
The pistol can be further enhanced by fitting a deflected spray extension. This unit allows the operator to spray at right angles and get into difficult to access spray areas, such as between pipes or close to brackets. This enables more areas to be sprayed and with a better quality coating than may have previously been possible. The extension uses the same consumable parts as a standard pistol.
Key features
- Fastest pistols on the market (up to 50kg/hr for continuous zinc)
- Stop/start version allows operator to stop spraying and leave the flame lit (e.g., whilst inspecting or moving the work piece)
- Variety of hose lengths to suit each application
- Wide range of wire sizes to suit many application and coating requirements
- Spreader and non-spreader versions to allow detail work or larger areas to be sprayed efficiently
- New, free standing or wall mounted control panel
- Safety shut-off valve
- Optional panel mounted oxygen regulator for long supplies setups
- Variable wire speed control
- Suitable for anti-corrosion wires plus some steels, copper and bronzes.
- Two stage air cap gives optimal setting for lighting and spraying
- Rugged construction combined with light-weight and balance for ease of handling
- Hanging hook for temporary storage or connection to spring balance
- Flow meters for optimal setting of parameters and fault finding
- Flow meters include large pointers for ease of checking from a distance
- Air Regulator and Filter (A.R.F.) unit supplies motor air, nozzle air
- Optional deflected extensions for access to difficult to spray areas
MK61 WIRE FLAME
The Metallisation MK61-FS is an oxygen-acetylene fuelled flame spray system, primarily for spraying engineering coatings of steels, bronzes, copper and importantly, molybdenum. The lightweight, robust pistol offers the possibility to reclaim damaged parts for small to medium sized applications. Molybdenum can also be sprayed with the MK61-FS as a soft bond coat through to a very hard, wear resistant coating. The MK61-FS system can be used for anti-corrosion coatings where propane is not readily available. The ‘FS’ stands for Free-Standing as the new control board can be free standing or wall mounted to suit all site or in-house applications.
Extended supplies package options are being increasingly used to maximise efficiency when working on large job sites such as refineries, petro-chemical sites and offshore structures. The extended supplies packages, up to 50m from cylinders to pistol, allows the cylinders to be remotely located whilst the operator moves around the job with just the pistol and occasionally moving the control panel. The length of supplies is limited by the pressure of the acetylene. Longer supplies are possible with the propane fuelled MK73-FS as well as faster spray rates for corrosion coatings.
New in 2014 is a more ‘site friendly’ control panel. It is more robust and offers further protection to the flowmeter and ARF unit. It can be wall mounted or will free-stand on the floor. The flow of hoses is neater than the previous unit.
Key features
- Stop/start version allows operator to stop spraying and leave the flame lit (e.g., whilst inspecting or moving the work piece)
- Wire sizes 1.5mm to 4.76mm (3/16”) to suit many application and coating requirements
- Suitable for Engineering wires, steels, copper and bronzes plus anti-corrosion materials.
- Spreader and non-spreader versions to allow detail work or larger areas to be sprayed efficiently
- New, free standing or wall mounted control panel with Safety shut-off valve
- Optional panel mounted oxygen regulator for long supplies setups
- Variable wire speed control
- Two stage air cap gives optimal setting for lighting and spraying
- Rugged construction combined with light-weight and balance for ease of handling
- Variety of hose lengths to suit each application
- Flow meters for optimal setting of parameters and fault finding
- Flow meters include large pointers for ease of checking from a distance
- Air Regulator and Filter (A.R.F.) unit supplies motor air, nozzle air.
- Optional deflected extensions for access to difficult to spray areas (anti-corrosion wires)
- Variety of wire dispense methods and packaging available
MK74 POWDER FLAME
Weighing only 1.85kg (4Lb), the Metallisation MK74 powder flame spray pistol can be hand held or machine mounted to spray a wide range of powders. Its robust construction will ensure long periods of trouble-free operation.
The MK74 is easy to ignite and has excellent flame stability, thanks to its nozzle system. A special air cap narrows the spray pattern to densify the coating which is particularly beneficial when spraying ceramics where very high deposit efficiencies can be achieved.
The MK74 can spray ceramic coatings as well as self fluxing alloys and all other metallic powders.
Key features
- High deposit efficiency
- Dense coatings
- Quiet operation
- Sprays ceramics and metals
- Simple to use
- Suitable for spray/fuse coatings
- Powder vibrator option for poor flowing powders
- Optional remote powder feeder
- Can spray some plastics
- Economic coatings
MK66-PC AUTO FLAME
The NEW Metallisation MK66E-PC is a fully automatic flame spray system with mass flow control, which offers the ability to produce the highest quality, repeatable coatings. The system provides a fully automatic sequence of ignition, main flame and wire feed. The wire feed is capable to be stopped during spraying without melting the wire back into the nozzle, even when left for extended periods. Fault sensors check for loss of flame, wire stoppages or wire out and can interlock to external automation to stop production and request assistance. These features ensure continued operation, improved coating quality and minimised downtime.
The system is PC controlled with distributed I/O, for extreme reliability, comprising a touch screen HMI (with optional keyboard), mass flow control gas box, and compact, electric drive pistol.
Key features
- Mass flow control of Oxygen, Propane Fuel Gas and Air = repeatability
- Easy to use, intuitive operator interface
- PC control with touch screen
- Optional keyboard control or operator interface unit
- Unlimited recipes and parameter recording
- Manual or fully sequenced start-up, operation and shut-down
- Safety interlocks to prevent running without Nozzle Air.
