Thermal Spray Consumables

Alloys International stock a complete range of consumables for all common thermal spray systems in use in Australia and Southeast Asia, including:
  • HVOF
  • HVAF
  • Twin-wire arc
  • Plasma
  • Flame spray
  • Spray and Fuse
With 30 years of experience in the maintenance and refurbishment industries, our expert staff are able to advise you on the best consumable to work with your equipment to help prevent specific combinations of erosion, corrosion, abrasion and impact. Some of our highest selling products are listed below. For a complete list of products, data sheets or MSDSs please your Alloys International representative.

Wires (Arc Spray, Spray and Fuse)

AI-1800SPNickel, Moly Aluminium superbond wire developed specifically for its high bond characteristics. 76MPa bond strength on blasted surface.As a bond coat under other thermal spray coatings onto any substrate.
AI-1801Molybdenum Spray Wire is an essentially pure molybdenum wire manufactured exclusively for flame spraying. It bonds directly to clean metal surfaces without other preparation, forming an ideal surface for the application of another flame sprayed coating. Used by itself, it provides a hard, long-wearing surface particularly where thin coatings are required.Use it to repair cracked engine blocks, heads and similar castings; damaged lathe ways; mold patterns and match plates.
AI-1801 Molybdenum Spray Wire is highly recommended for inside diameters and flat surfaces either by itself or as a bond coat.
AI-1804Machinable self-bonding Nickel based alloy. High bond strength and easy to apply.Bearing journals, pump plungers, worn parts which cannot be ground.
AI-1805Iron-based self bonding alloy with outstanding corrosion resistance and good machineability. 30% Chrome.Boilers, heat exchangers, petrochemical industry, pump housings, pulp and paper industry.
AI-1820Nickel-Chrome corrosion resistant coating, self bonding. Can be used as bond coat where applications don’t allow aluminium. Machineable.Thermal barrier coatings, corrosion resistant coatings up to 982°C
AI-1822Martensitic 420 high chrome stainless steel coating. Produces a hard, dance coating with excellent wear resistance. Difficult to machine. Requires bond coat.Bearing journals, hydraulic rams, pistons, bearing housings.
AI-1825AI-1825 is made exclusively for arc spraying. The material is extremely effective against corrosion and stress cracking in caustic mediums. It is also very corrosion resistant in a broad range of acidic and chloride environments at a range of temperatures.AI-1825 coupled with an appropriate sealer should also be considered for service in many acidic environments. It is particularly effective in a phosphoric acid environment.
AI-1844316 Stainless steel wire designed specifically for arc spraying. Easy flowing wire. Requires bond coat.Any application providing a coating of corrosion resistant 316 stainless.
AI-1850MFSpray-and-fuse wire. Designed for subsequent fusing after application. Produces metallurgically bonded deposit with high wear resistance. Post fusing coating must be ground. 50-55HRC.Applications involving severe high stress abrasion combined with low impact at temperatures not exceeding 450°C.
AI-1855Austenitic spray wire made exclusively for arc spraying. Excellent corrosive properties and machineable.Where dense, corrosion resistant coatings are required. Seal rings, gland casings, valve plugs etc.
AI-1860MFSpray-and-fuse wire. Designed for subsequent fusing after application. Produces metallurgically bonded deposit with high wear resistance. Post fusing coating must be ground. 60-62HRC.Applications involving severe high stress abrasion combined with low impact at temperatures not exceeding 450°C.
AI-1866Low-shrink wear resistant steel wire made exclusively for arc spraying. Unlimited coating thickness without cracking. 220HB. Fully machineable.Bearing journals, shafts, any application requiring a wear resistant machineable coating.
AI-1867AI-1867 is an alloy especially manufactured for arc spraying components for reclamation and corrosion protection. It may also be used as an overlay on copper prior to build-up with a variety of alloys but more often as an overlay on steel and iron-based components. Best results are obtained in combination with a bond layer of AI-1800 or AI-1875.Bearing surfaces in bores and on journals, high load and/or high pressure applications, tough and wear resistant alloy used as a buildup layer under harder top layers. Also provides excellent corrosion protection in saline environments.
AI-1870Hardfacing alloy designed exclusively for arc spraying. Hard, abrasive and wear resistant coating. Work hardens in service. Impressively tough for a coating this hard. Finish by grinding only. Requires bond coat. 53HRCApplications up to 950°C involving corrosion, abrasion.
AI-1872SDA self-bonding hardfacing alloy designed exclusively for arc spraying. Reduces overall coating cost by elimination of bond wire. Requires bond coat. Work hardens in service up to 53HRc.Applications up to 950°C involving corrosion, abrasion.
AI-1875AI-1875 is a solid Nickel Aluminium bond wire produced specifically for metal spraying. It has been introduced as an economical alternative to AI-1800 bond wire where ultimate bond strength may not be required. AI-1875 can be finished by either machining or grinding. It can be applied directly on to a smooth, chemically cleaned surface where rough machining or grit blasting is not possible. It is recommended however, that a Class 2 white finish be achieved prior to spraying, by grit blasting with a Chilled Iron G24 grade grit or rough machined to maximise bond strength.
AI-1876Wire made for arc spraying which is often considered to be the most versatile corrosion resistant alloy available and is often used where reactionary conditions are likely to occur or in multi-purpose plants.For reaction vessels, tanks, piping, fittings etc in Chemical and Petrochemical plants, pollution control equipment, scrubbers, paper pulp processing, specifically the strong oxidizing media (ferric chloride, cupric chloride), chlorine, hot contaminated media (organic and inorganic), formic and acetic acids, sea-water/brine heat exchangers, flue gas desulphurization, fertilizer processing, applications requiring resistance to chloride pitting and stress corrosion cracking, resistance to oxidizing atmospheres up to 1030°C.
AI-1884Copper aluminium multi bronze with a high Ni and Fe addition. It is used for arc spray cladding primarily on cast iron materials and steel. It is resistant to sea water and is cavitation resistant.Recommended for all general metallizing work with bronze. This material is extremely effective where surface preparation may be less than optimum; eg: on cast iron or steel.
AI-1888Aluminium Bronze wire made exclusively for arc spraying. Self-bonding alloy.Reclaiming bronze components, protective layers on cast iron and unknown steel components, bearing journals and housings. Corrosion resistant applications.
AI-1892De-oxidised copper wire made exclusively for arc spraying. Excellent thermal and electrical conductivity. Requires bond coat.Applications requiring good thermal conductivity including dies, carbon brushes, discharge electrodes, earthing conductors
AI-1893Pure Aluminium wire designed for arc spray. Self-bonding.For atmospheric and marine galvanic corrosion prevention of steel structures.
AI-1894Pure Zinc arc spray wire.For cheap protection of steel parts in-lieu of paint. Poor resistance to acidic corrosion.

Ceramic Powders (Plasma)

AI-1010Aluminium Oxide Ceramic Powder exhibiting high hardness and outstanding corrosion resistance. 65HRc.Sliding wear surfaces such as pump shafts, mechanical seals, plungers, slurry pump liners.
AI-1011Aluminium Oxide ceramic powder developed primarily
for plasma spraying
Sliding or rotating wear surfaces such as pump shafts and sleeves, mechanical seal faces,
pump plungers, sealing rings etc.
AI-1025Chrome oxide ceramic powder exhibiting high hardness and outstanding corrosion resistance.Applications up to 540°C requiring smooth, hard abrasion and corrosion resistance. Pump sleeves, wear rings, fans.
AI-1036Chrome oxide/silicon dioxide/titanium dioxide ceramic powder. The most abrasion resistant of the ceramic powders. Higher impact resistance than due to the presence of silicon dioxide.Applications involving fine particle abrasion. Suitable for corrosive environments when properly sealed.
AI-1097Titanium dioxide. Dense coating. 53HRc.Applications up to 540°C requiring abrasion resistance. Good for coating titanium components subject to wear.

High Velocity Powders (HVOF / HVAF)

AI-2601Tungsten carbide/nickel spherical spray powder. Produces extremely hard, dense depositsApplications involving low stress fine particle abrasive wear, fretting, and erosion. Applications where cobalt can’t be used due to corrosion.
AI-2606Cobalt based alloy 6 (similar to Stellite 6). 45-50HRc. Machinable with a tungsten carbide tool. Excellent resistance to erosion, fretting and corrosion up to 800oCFor reclamation where elevated temperatures and corrosive media are present. Ball valves.
AI-2645Nickel based coating for corrosion resistance. Hard but machineable. 40-44HRc.Valve seats, high speed shafts, any application requiring machineable coating which is also reistant to fine particle erosion or metal-to-metal wear.
AI-2672Tungsten carbide/Cobalt. Extremely hard, abrasion resistant coating. Can be ground and superfinished to mirror finish. Max operating temperature 550oCPump sleeves, ID fans, mechanical seals, seal journals. Application subject to high abrasion.
AI-2675Chrome carbide/nickel chrome. Corrosion resistant hard coating for service in temperatures up to 750oC. Can be ground and superfinished to mirror finish.Hydraulic pistons.
AI-2682316 Stainless SteelApplications involving mild corrosion.
AI-2685Tungsten Carbide/Chrome Carbide/Nickel Chrome. Provides outstanding corrosion resistance in abrasive applications. High service temperature of 760°CChemical industry applications, offshore and marine. Pump seals, pulp and paper applications.
AI-2686Tungsten carbide/Cobalt/Chrome. Max operating temperature 550°C.Applications requiring improved corrosion/abrasion resistance compared to AI-2672

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