File: 1.9.1.
2-01T
Issue: Q11121
Supercedes: 010823
Praxair and TAFA Arc Spray Aluminum Wire - 01T
Material Review: marine and similar environmental exposures. For
exposure to acid conditions, soft water and hard
water, aluminum is the best choice of the arc spray
Made exclusively for arc spraying. Characteristics wires.
are its resistance to atmospheric, chemical, and high
temperature corrosion, and its electrical and heat
High Temperature Corrosion - Coatings are applied
conductivity properties. The bond strength of arc
to increase the service life of steel heat-treating
sprayed aluminum is superior to gas sprayed. Arc
equipment, automotive engine exhaust systems, to
Spray 01T Aluminum Wire can be sprayed with any
protect against thermal shock, and to reline jet
Praxair and TAFA Arc Spray gun.
engine combustion chambers. (See Bulletin 2.6.1).
An aluminum sealer is recommended for coatings
Arc Spray 01T Aluminum Wire meets the following
used for temperatures up to 1000°F.
specifications: Dept. of Defense MIL-W-6712C Table
II, Aluminum, PWA 1320F and SNECMA DMR33-
012, Garrett FP5045, and GE CF6 Overhaul Manual Electrical Conductivity - Coatings applied to non-
operation number 70-49-40 as a substitute for 70- metallic material joints to dissipate static electricity
49-01. build-up including applications where zinc cannot be
used because of weight or chemistry. This includes
CAUTION: All Praxair and TAFA wires have been instrument nuts and missile systems, and applying
optimized for arc spraying. Use of alternate wires conducting areas to surfaces requiring electrical
usually cause problems such as excessive tip wear, conductivity are prime uses.
spitting and feeding problems. We only recommend
Praxair and TAFA certified wires. Heat Conductivity - Commercial and residential
kitchen utensils have been sprayed to achieve an
even flow and distribution of heat. Through the use
Application Review: of its weight characteristics and heat conductivity
properties, aluminum coating has been applied to
Atmospheric Corrosion - The aluminum coating acts brake discs to achieve necessary abrasion
as a galvanic corrosion inhibitor and also forms an resistance and good heat flow to aid the cooling of
oxide film producing a protective coating, thus, is the discs under demanding race conditions.
recommended under a variety of environmental
conditions and is used exclusively on submerged Repair of blow holes in aluminum, magnesium and
water applications. For long term anti-corrosive their alloy castings to salvage.
applications, aluminum should be covered with a
protective 5-8 mil layer of a suitable sealer in all but Anti-skid - An extremely low atomizing air pressure
mild rural applications. Consult Praxair and TAFA spray mode gives a coarse anti-skid coating for
for specifications. Typically a phosphate primer is walkways and shipdecks.
sprayed directly on a freshly sprayed aluminum
surface followed by either a vinyl copolymer (colored Skin Repair - Praxair and TAFA's Arc Spray has
or aluminum pigmented or a coal tar epoxy the latter been approved for cosmetic repair of scratches on
for severest environments). aircraft surfaces (Bulletin 2.7.2.5.1).
Chemical Corrosion - Useful in protection of Ceramic Bond Coat - Praxair and TAFA Arc Sprayed
chemical processing equipment, oil refining aluminum is an extremely good bond coat on
equipment, commercial equipment in contact with ceramic materials such as zinc oxide, carbide, etc.
Distributed by Astro Alloys Inc. Houston, Texas 1-877-937-3838
The high temperature of the droplets and their high Miscellaneous - Aluminum Alloy 5356 gives an as
velocity result in extremely tenacious bonds (1000 - sprayed hardness of 80 Rh compared with 01T of 60
3000 psi) on clean surfaces. In most cases, grit Rh under the same spray conditions.
blasting or preheating is not required. Merely grind
as a finished condition. The high bond strength
makes aluminum an ideal coating for varistor or
thermistor applications. Consult factory for details
since many automated systems and much data is
available in this area.
Composition
Aluminum 99.5 Percent (min.)
Coating Physical Properties
Wire Size 1/16" (1.6 mm), 2.0 mm
Deposit Efficiency 69 Percent*
Melting Point 1215°F (657°C) (approx.)
Bond Strength 1613 psi (11.1 MPa) clean surface **
4375 psi (30.2 MPa) blasted surface
Coating Texture (as sprayed) Variable *, *** (see next page)
Hardness R15T 40-50 (RB 30-75 converted)
55 Knoop100
Coating Density 2.51 gm/cc****
Oxide Content Less than 2 percent
Porosity 2.1 percent
2
Coating Weight 0.013 lbs/ft /mil
Shrink 0.007 in/in (cm/cm)
Spraying
Spray Rate 6 lbs/hr/100 amps (2.7 kg/hr/100 amps)
2 2
Coverage (wire consumption) 0.3 oz/ft /0.001" (0.37 kg/m /100 microns)
Spray Pattern***** (approximate 8" standoff) Cross Nozzle/Positioner - 1" (2.5 cm)
vertical height x 1 3/4" (4.4 cm) width
Slot Nozzle/Positioner - 2" (5 cm)
vertical height x 1" (2.5 cm) width
Length of wire per lb 282 ft (1/16"), 176 ft (2 mm)
Power Unit
For aluminum only, connect leads to center and left
(+) terminal.
* Depends on air pressure, amperage, standoff, nozzle cap and target size
** Depends on surface temperature - consult Praxair and TAFA.
*** 6" standoff, 40 psi - 8830, depends on air pressure - fine with high psi, average with medium psi, and
rough with low psi
**** Depends on atomizing air pressure
***** Higher air pressures, smaller wire (1/16), and lower amperage with red nozzle cap gives smallest
diameter pattern.
Page 2
Distributed by Astro Alloys Inc. Houston, Texas 1-877-937-3838
Spraying Procedures: These are starting parameters only. Optimum parameters will vary depending
on applications, utilities, environment, spray rate and equipment
Coating Type
Standard 8830/35 Standard 8850 Standard 9000
c C c
Atomizing Air Pressure: Primary 60 50 50
--- --- ---
Secondary
Contact Tip 450044 450491 450044
Nozzle Cap Green Green Green
Nozzle/Positioner (Cross=C; Long C Long C Long C
Slot=S)
a
Arc Load Volts 28-30 29-31 29-31
b
Amps 50-300 50-300 50-300
Standoff Inches 4-5 2-4 2-4
Coating Thickness/Pass-mils 3-5 3-5 3-5
Coating Texture-Microinches aa 200-350 200-350 200-350
Using excessive voltage reduces quality of coating. Voltage should be adjusted to give minimum noise and
smooth arc operation. Excessive voltage causes larger particles and poor spray pattern. Too low a voltage
will cause popping.
Be sure not to overheat substrate even if this means stopping to allow cooling, use air jet cooling if greater
speed is required. Note that on some applications where preheating is tolerable, preheating work to 300°F
can improve bond and deposit efficiency.
NOTE: Standard air caps and positioners can be used in 8830, 8850 or 9000 systems.
a When using power lead extensions other than the normal 12 foot furnished, the voltage must be increased by
approximately 3.4 volts per 50 foot of extension; i.e., add 3.4 volts to the recommended voltage setting for a
given wire if the extension is increased to a 50 foot length.
b Can vary between 50-300 depending on size of workpiece and traverse speed.
c For finer finish, raise air pressure at point of finish.
Page 3
Distributed by Astro Alloys Inc. Houston, Texas 1-877-937-3838
Cautions
1. Use contact tips designed for aluminum. These
tips will have a groove on the taper of the tip.
2. Use proper power supply tap - see previous
page.
Aluminum is the most difficult of all wires to spray
and must be kept very clean, do not allow surface of
wire to become dusty, damaged or kinked.
A high quantity of dust is produced and a minimum
of 5000 SCFM extraction near gun should be used.
In a closed room or booth, a minimum of 10,000
SCFM should be used.
Aluminum or magnesium substrates should be
blasted with a pressure which does not allow an
entrapment of the grit in the substrate. Use 30 mesh
aluminum oxide with a suction blaster or a pressure
blast at 55 psi (supply not nozzle pressure) or less.
Finishing:
A variety of finishes can be achieved through
machining with either speed or carbide tools,
sanding, polishing or burnishing.
Hazards:
Copyright 2000 Praxair Technology, Inc. All rights reserved
Observe normal spraying practices, respiratory www.praxairthermalspray.com
protection and proper air flow patterns advised. For [email protected]
general spray practices, see AWS Publications AWS Telephone: 1-317-240-2650
C2.1-73, "Recommended Safe Practices for Thermal Fax: 1-317-240-2596
Spraying," and AWS TSS-85, "Thermal Spraying, Praxair, the Flowing Airstream design and Making our planet more
Practice, Theory and Application". Thermal spraying productive are trademarks or registered trademarks of Praxair
is a completely safe process when performed in Technology, Inc. in the United States and/or other countries.
accordance with proper safety measures. Become Other trademarks used herein are trademarks or registered
familiar with local safety regulations before starting trademarks of their respective owners.
spray operations. DO NOT operate your spraying Printed in the United States of America 05-2000
equipment or use the spray material supplied before
you have thoroughly read the Praxair and TAFA
Instruction Manual.
A Material Safety Data Sheet will be sent with each
initial purchase and updated as required. www.tafa.com
[email protected]DISREGARDING THESE INSTRUCTIONS MAY BE Telephone: 603-224-9585
DANGEROUS TO YOUR HEALTH. Fax: 603-225-4342
TAFA is constantly improving its products, therefore specifications are
The information provided herein is believed to be subject to change without notice
accurate and reliable; however, results may vary TAFA Incorporated is a Praxair Surface Technologies company.
with workpiece preparation and operator
technique. Praxair and TAFA warrants only that
the wires are free of defects in material and
workmanship. No other warranty is expressed
or implied.
Page 4
Distributed by Astro Alloys Inc. Houston, Texas 1-877-937-3838
