Wire BrochureandBulletins

Wire Solutions
Catalog
Praxair and TAFA
thermal spray wires
Praxair Surface Technologies, Inc. and TAFA

Incorporated offers a complete line of arc spray wires
in its portfolio of thermal spray materials. Proud of
our role in the emergence and growth of the arc spray
process, we continue to develop and refine thermal
spray wires of all types solid or cored, soft or hard
to help you take full advantage of the exceptional value
arc spray provides.
Whether your application calls for a reliable bond coat,

dimensional restoration or resistance to wear and
corrosion, Praxair and TAFA has a wire to meet the
challenge. Understanding that not all wires are
alike in part because we optimize wires for superior
arc spray coatings we provide materials that
perform every time. And we offer the complete
system, including six hardware options, to start you
on the way to productive solutions.
When you search for the right thermal spray wire,

remember the company that built its reputation on arc
spray technology: Praxair and TAFA. Let us work
with you to continue to develop and perfect quality arc
spray wires and coatings.
Phone: 1-603-223-2100
Fax: 1-603-225-4342
E-mail: psti-info@praxair.com Quality thermal spray wires must be made to
tight compositional tolerances, have the
appropriate surface finish, and be spooled
properly for consistent performance.
Exceptional wires for
superior
superior coatings
We recognize that high quality spray All Praxair and TAFA wires are engi- testing and analysis assure that the
equipment without compatible, first-rate neered and manufactured exclusively targeted characteristics are achieved.
coating materials can lead to less for the specialized needs of thermal
than desirable coatings. For arc spray, spray. Strict specifications and produc- Praxair and TAFA wires are available in
only wires designed and produced tion controls guarantee that each a number of packaging options. We
for thermal spraying ensure trouble-free wire is manufactured to a precise met- offer several sizes of level-layer wound
application and superior, consistent allurgical composition and free from spools and larger dispensing contain-
coatings. defects such as slivers or contaminants. ers for high volume applications.
Care is taken to ensure that our wires
have the proper physical properties for
thermal spraying tensile strength,
hardness, and surface finish and that
they are properly spooled for reliable
performance. Post manufacturing
An extensive inventory
of wires, available in
25 or 30 pound spools
as well as bulk
pay-off packs, assures
prompt delivery and
reinforces our commit-
ment to the growth
and development of
arc spray applications.
wires
Metal and alloy wires
Wire Material Diameter Coverage Spray Rate Approved Specs Application Data
Name (/ft2/0.001") (/h/100 A)
(/m2/100 m)
AI-1800 Nickel Aluminum 1/16" (1.6 mm) 0.8 oz 10 lbs Bond Coat
Molybdenum 1.0 kg 4.5 kg Oxidation, Shock and
Abrasion Resistance
Alcro Iron Chrome Aluminum 1/16" (1.6 mm) 0.8 oz 10 lbs Good for Buildup
1.0 kg 4.5 kg Excellent Wear Resistance
01A Aluminum 1/16" (1.6 mm) 0.3 oz 6 lbs AWS C2.25/C2.25M Dimensional Restoration
12% Silicon 0.3 kg 2.8 kg PWA 36935 Aircraft Approved
(PWA 271-35 Rev G)
GE B50TF92
(Chemical Composition)
01P Aluminum 11gauge (2.3 mm) 0.3 oz 6 lbs AWS C2.25/C2.25M Corrosion Protection
1100 1/8" (3.2 mm) 0.3 kg 2.8 kg
01S Aluminum 1/16" (1.6 mm) 0.3 oz 6 lbs AWS C2.25/C2.25M Dimensional Restoration
6% Silicon 0.3 kg 2.8 kg FP5045 Type VIII, Rev AB Aircraft Approved
01T Aluminum 1/16" (1.6 mm) 0.3 oz 6 lbs AWS C2.25/C2.25M Corrosion Protection
1/8" (3.2 mm) 0.3 kg 2.8 kg FP5045 Type VI, Rev AB Electrical Conductivity
GE Manual # 70-49-40 Aircraft Approved
(Alternate to 70-49-01)
02A Zinc Aluminum 2 mm 0.8 oz 21 lbs Corrosion Protection
11gauge (2.3 mm) 1.0 kg 9.5 kg
1/8" (3.2 mm)
3/16" (4.8 mm)
02T Zinc Tin 2 mm 0.9 oz 45 lbs Capacitors: Solderable
1.1 kg 20.4 kg Coating
02W Pure Tin 2 mm 0.9 oz 50 lbs AWS C2.25/C2.25M Sputtering Targets
1.1 kg 22.7 kg Electrical Contacts
EMI/RFI Shielding
02Z Zinc 1/16" (1.6 mm) 0.9 oz 21 lbs AWS C2.25/C2.25M Corrosion
2 mm 1.1 kg 9.5 kg EMI/RFI Shielding
1/8" (3.2 mm) Electrical Conductivity
3/16" (4.8 mm)
04T Babbitt 1/16" (1.6 mm) 0.9 oz 50 lbs AWS C2.25/C2.25M Bearing Reclamation
2 mm 1.1 kg 22.7 kg Capacitors
1/8" (3.2 mm)
05T Copper 1/16" (1.6 mm) 0.9 oz 11 lbs Electric Conductivity
1/8" (3.2 mm) 1.1 kg 5.0 kg Copper Reclamation
Decorative Coatings
06C Nickel Chrome 1/16" (1.6 mm) 0.8 oz 11 lbs Conforms to PWA 1317D Oxidation Resistance
1.0 kg 5.0 kg Aircraft Approved
06T Nickel 1/16" (1.6 mm) 0.8 oz 10 lbs AWS C2.25/C2.25M Corrosion Protection at
1.0 kg 4.5 kg High Temperatures
10T Aluminum Bronze 1/16" (1.6 mm) 0.9 oz 9 lbs Bond Coat
1/8" (3.2 mm) 1.1 kg 4.1 kg Reclamation
Cavitation
Aircraft Approved
11T Aluminum Bronze 1/16" (1.6 mm) 0.9 oz 9 lbs Cavitation
Nickel 1.1 kg 4.1 kg Reclamation of Sliding
Components
Corrosion Protection
12T Brass 1/16" (1.6 mm) 0.9 oz 9 lbs Use Where Tobin Bronze
1.1 kg 4.1 kg is Required
Pump Impellers
Bronze Castings
13T Molybdenum 1/16" (1.6 mm) 1.1 oz 10 lbs PWA 36913 (PWA 271-13 Rev F) Galling and Scuffing
1/8" (3.2 mm) 1.3 kg 4.5 kg AWS C2.25/C2.25M Resistance
MSSR 9507/102 Aircraft Approved
14T Titanium 1/16" (1.6 mm) 0.4 oz 3 lbs ASTM B348/Grade 1 Medical Implants
0.5 kg 1.4 kg ASTM F67-89/Grade 1
(Chemical Composition)
16T Silicon Bronze 1/16" (1.6 mm) 0.9 oz 9 lbs Cosmetic Repairs
1.1 kg 4.1 kg Decorative Coatings
Automotive Approved
wires
Metal and alloy wires
Name (/ft2/0.001") (/h/100 A)
(/m2/100 m)
30S Silver Copper Zinc 1/16" (1.6 mm) 1.0 oz 12 lbs GE B20A4 (Chemical Composition) Stationary Seals in Aircraft
1.2 kg 5.4 kg GE Manual # 70-49-44 Engines
FAA RDE#00-630 Good Rub Wear
CFM70-48-16-340-007 Characteristics
30T Low Carbon Steel 1/16" (1.6 mm) 0.9 oz 10 lbs Dimensional Restoration of
1.1 kg 4.5 kg Mismachined and Worn Parts
38T High Carbon Steel 1/16" (1.6 mm) 0.9 oz 10 lbs AWS C2.25/C2.25M Reclamation
(0.80 C) 1.1 kg 4.5 kg Wear and Erosion Resistance
ID Fans
39T High Carbon Steel 1/16" (1.6 mm) 0.9 oz 10 lbs Excellent Wear Resistance
(1.0 C) 1.1 kg 4.5 kg Harder than 38T
45CT Nickel Chrome 1/16" (1.6 mm) 0.9 oz 11 lbs Protection Against High
Titanium 1.1 kg 5.0 kg Temperature Sulfidation
55T 18/5 Stainless 1/16" (1.6 mm) 0.8 oz 10 lbs AWS C2.25/C2.25M Low Carbon
200 Series Stainless 1/8" (3.2 mm) 1.0 kg 4.5 kg FP5045 Type IV, Rev AB Low Shrinkage
Good Machinability
Aircraft Approved
58T Copper Nickel Indium 1/16" (1.6 mm) 0.8 oz 10 lbs GE B50TF72 CL A Fretting Resistance
1.0 kg 4.5 kg (Chemical Composition) Dense, Low Oxide Coatings
GE Manual #70-49-05 Aircraft Approved
60T 420 Stainless Steel 1/16" (1.6 mm) 0.8 oz 10 lbs AWS C2.25/C2.25M Reclamation
1/8" (3.2 mm) 1.0 kg 4.5 kg OMAT#3/45D Low Shrinkage Allows Thick
FP5045 Type V, Rev AB Buildups
Good Wear Resistance
Aircraft Approved
61T 430 Stainless Steel 1/16" (1.6 mm) 0.8 oz 10 lbs Slightly More Machinable and
1.0 kg 4.5 kg Better Corrosion Resistance
than 60T
70T Nickel Copper 1/16" (1.6 mm) 0.8 oz 10 lbs AWS C2.25/C2.25M Marine Corrosion Protection
1.0 kg 4.5 kg Print Rolls
71T Nickel Chrome 1/16" (1.6 mm) 0.8 oz 11 lbs Prohibits Caustic Corrosion
Molybdenum 1.0 kg 5.0 kg Paper Mill Digesters
75B BondArc 1/16" (1.6 mm) 0.9 oz 10 lbs PWA 36937 (PWA 271-37 Rev F) Bond Coat
Nickel 1.1 kg 4.5 kg GE Manual # 70-49-38 Aircraft Approved
5% Aluminum (Alternate to 70-49-10) Oxidation /Abrasion
OMAT#3/229 Resistance at High
FP5045 Type XV, Rev AB Temperatures
BF Goodrich Ltr 1623
CFM 70-48-14-340-005
AWS C2.25/C2.25M
77T Alloy C-276 type: 1/16" (1.6 mm) 0.9 oz 11 lbs Acidic and Hot Gas
Nickel Chrome 1.1 kg 5.0 kg Corrosion Resistance
Molybdenum
78T Alloy 718 type: 1/16" (1.6 mm) 0.8 oz 11 lbs GE Manual # 70-49-45 Aircraft Engine Dimensional
Nickel Chrome 1.0 kg 5.0 kg CFM 70-48-17-340-008 Restoration
Molybdenum Acidic and Hot Gas
Corrosion Resistance
79B Nickel 1/16" (1.6 mm) 0.9 oz 10 lbs OMAT#3/90A High Temperature Oxidation
20% Aluminum 1/8" (3.2 mm) 1.1 kg 4.5 kg FP5045 Type II, Rev AB and Abrasion Resistance
Aircraft Approved
80T 18/8 Stainless Steel 1/16" (1.6 mm) 0.8 oz 10 lbs AWS C2.25/C2.25M Corrosion Protection
304 Series Stainless 1.0 kg 4.5 kg Dimensional Restoration
Print Rolls
85T 316 Stainless Steel 1/16" (1.6 mm) 0.8 oz 10 lbs Corrosion Protection
1.0 kg 4.5 kg Dimensional Restoration
88T 300 Series Stainless 1/16" (1.6 mm) 0.8 oz 9.5 lbs Corrosion Protection
1.0 kg 4.3 kg Dimensional Restoration
Print Rolls
204M Kirksite type 1/16" (1.6 mm) 0.8 oz 22 lbs Proprietary Alloy Used to Create Metal Faced
1.0 kg 10 kg Tooling
wires
Cored wires
Name (/ft2/0.001") (/h/100 A)
(/m2/100 m)
35 MXC Iron-based High 1/16" (1.6 mm) 0.8 oz 8.5 lbs Traction and Anti-Skid
Carbon Alloy 1.0 kg 3.9 kg Coatings
Wear Resistance
37 MXC Iron Chrome Carbon 1/16" (1.6 mm) 1.0 oz 8 lbs High Hardness
1.2 kg 3.6 kg Excellent Wear Resistance
73 MXC Nickel Chrome 1/16" (1.6 mm) 0.8 oz 8.5 lbs PWA 36947 (PWA 271-47 Rev F) Oxidation and Corrosion
Aluminum 1.0 kg 3.9 kg MSSR 9507/14 Resistance
GE Manual # 70-49-39 Aircraft Approved
(Alternate to 70-49-21)
FP5045 Type XVIII, Rev AB
74 MXC Nickel Aluminum 1/16" (1.6 mm) 0.8 oz 8.5 lbs MSSR 9507/35 Medium Hardness for
Molybdenum 1.0 kg 3.9 kg GE B50TF166 Bearing Wear Applications
(Chemical Composition) Particle Erosion Resistance
FP5045 Type XVI, Rev AB Aircraft Approved
76 MXC Nickel Chrome 1/16" (1.6 mm) 0.8 oz 7 lbs GE B50TF296 Bond Coat to Ceramics
Aluminum 1.0 kg 3.2 kg (Chemical Composition) Oxidation and Heat
Yttrium Resistance
Aircraft Approved
90 MXC Iron Chrome Nickel 1/16" (1.6 mm) 1.0 oz 7 lbs Corrosion and Wear
1.2 kg 3.2 kg Protection
95 MXC Iron Chrome Boron 1/16" (1.6 mm) 1.0 oz 8 lbs Corrosion and Wear
ID Fans
Boiler Tubes
96 MXC Iron Nickel Chrome 1/16" (1.6 mm) 1.0 oz 7.5 lbs High Temperature Corrosion
Abrasion Resistance
97 MXC Nickel Chrome 1/16" (1.6 mm) 1.0 oz 6.5 lbs Abrasion and Wear
Tungsten Carbide Iron 1.2 kg 3.0 kg Resistance
98 MXC Iron Chrome Nickel 1/16" (1.6 mm) 1.0 oz 8 lbs Corrosion and Wear
106 MXC Cobalt Nickel Chrome 1/16" (1.6 mm) 0.9 oz 6.5 lbs Abrasion and Fretting
Tungsten 1.1 kg 3.0 kg Resistance in High
Temperature Environments
444 MXC Nickel Chrome 1/16" (1.6 mm) 0.8 oz 8.5 lbs EMS 56762 Wear and Corrosion
Aluminum Molybdenum 1.0 kg 3.9 kg Resistance
Dimensional Restoration of
Bearing Areas
Cored wire advantages

Praxair and TAFA is the thermal spray
leader in the development and manu-
facture of cored wires. Advanced materi-
als engineering allows compositions
that cannot be drawn as solid wires to
be produced by enclosing
powders in a metallic sheath.
Application of cored wire technology

has resulted in arc spray coatings
replacing plasma coatings for many
aircraft engine repairs and industrial
wear applications.
Arc spray
options
equipment options
Praxair and TAFAs complete family of Arc Spray Systems offers

something for everyone. Whether your applications demand
high productivity in a controlled work cell or occasional
repairs performed by a well-trained operator, our line of push,
pull or push/pull twin-wire arc systems has a gun that meets
your performance and budget requirements.
8830 8835 BP400

Is an established, heavy-duty unit using an Is a machine-mount version of the 8830, Utilizes pusher technology for easier hand-
air motor drive to pull the wire to the gun. using a D.C. electric drive to pull the wire to held operation. The BP-400 features a
The 8830 produces outstanding arc spray the gun. Engineered for repeatability, the lightweight gun and is a proven performer,
coatings with virtually any type of wire: hard, 8835 is renowned for reliability and robust producing consistent coatings every day
soft, solid or cored. performance. in shops around the world.
9000 Spare Parts Contact Tips

Is a push/pull unit designed for automated Only Praxair and TAFA genuine spare parts Rely on Praxair and TAFA high quality contact
spraying yet offers the hand spraying should be used in your thermal spray equip- tips for your arc spray guns. Standard contact
option. The 9000 is widely utilized in shops ment. Designed and manufactured to precise tips and long-life contact tips are available for
that overhaul gas turbine engines due to tolerances, Praxair and TAFA spare parts different sized wires. Praxair and TAFA
its unsurpassed coating quality and ensure proper system operation providing designs and manufactures contact tips for
repeatability. optimal equipment operation. Models 8830, 8835, 9000, 8850, BP400 and
ID extensions.
In todays competitive marketplace, improved productivity and

reduced costs are key business goals. Meeting them requires
a total-capabilities resource that can provide customized
solutions for gases, equipment and supply options, as well as
thermal spray technology and related services.
They require a company like Praxair, North Americas largest

industrial gases supplier, with the ability to offer local coverage
and international reach.
As your single-source supplier, Praxair can help reduce your

total cost of ownership as well as improve productivity, provide
competitive pricing and deliver supply reliability.
Copyright 2004 Praxair Technology, Inc. TAFA Incorporated
All rights reserved 146 Pembroke Road
Concord, NH 03301
Praxair Surface Technologies, Inc.
USA
1555 Main Street
Indianapolis, IN 46224 www.praxair.com/thermalspray
USA psti-info@praxair.com
Telephone: Telephone:
1-317-240-2650 1-603-224-9585
Fax: Fax:
1-317-240-2596 1-603-225-4342
Praxair Services GmbH & Co. KG TAFA Incorporated is a Praxair Surface Technologies
Am Muhlbach 13 company.
D-87487 Wiggensbach
Praxair and TAFA is committed to continuous
Germany
product improvement. Specifications, appearances
Telephone: and dimensions are subject to change without
+49-(0) 8370-9207-0 notice.
Fax: All product photographs are not to scale and should

+49-(0) 8370-9207-20 be used for information only. Photos might not repre-
sent the current version of products or packaging and
www.praxair.com/thermalspray
should not be used for comparison purposes.
psti-info@praxair.com
BondArc, 45CT, 75B and MXC are registered trade-
Praxair, the Flowing Airstream design and Making
marks of TAFA Incorporated.
our planet more productive are trademarks or
registered trademarks of Praxair Technology, Inc.
in the United States and/or other countries.
Coverage values and Spray Rates are estimates

and are subject to variation based on operating
conditions and system parameters.
Thermal spray coatings produced by wire-based

processes require the use of a sealer to be effec-
tive in corrosive environments.
The information contained herein is offered for use

by technically qualified personnel at their discre-
tion and risk without warranty of any kind.
Printed in the United States of America

04-2004
PT-0001 15K
Return to Wire Brochure
File: 1.9.1.2-01A
Issue: 011111
Supercedes: M11103
Praxair and TAFA Arc Spray Silicon

Aluminum Wire - 01A
Material Review:
Made exclusively for arc spraying, aluminum silicon alloy wire produces coatings that are slightly less corrosion-
resistant than with an aluminum coating. Advantages achieved with the coating are a harder surface, does not
gall like aluminum; more dense and finer texture and faster spray adhesion.
Arc Spray 01A, Silicon Aluminum wire, can be sprayed with any Praxair and TAFA Arc Spray gun.
Arc Spray 01A Silicon Aluminum wire meets the following specifications: Department of Defense Specification
MIL-W-6712C, Table II, Silicon Aluminum, PWA 36935 for PWA 271-35 Rev D, GE B50TF92S2CLA, SNECMA
DMR33-027 and BF Goodrich Wheel & Brake Service Letter 1623.
CAUTION: All Praxair and TAFA wires have been optimized for arc spraying. Use of alternate wires usually
cause problems such as excessive tip wear, spitting and feeding problems. We only recommend Praxair and
TAFA certified wires.
Application Review
Recommended for any aluminum build-up on worn machine parts, machine element work, altering the shape of
aluminum castings in most model work, or repairing blow-holes in aluminum patterns.
Praxair and TAFA 01A produces coatings which are harder and slightly denser than coatings produced by Praxair
and TAFA 01T pure aluminum. Sprayed coatings of 01A are currently being used for the repair of worn parts of
jet engines and the restoration of dimension to jet engine parts which were mis-machined in manufacture.
Silicon Aluminum 01A is applicable to the spraying of glass for a heat-reflective or light-reflective surface.
Composition:
Silicon 12 Percent
Aluminum Balance
Coating Physical Properties

Wire Size 1/16" (1.6 mm)
Deposit Efficiency 69 Percent*
Melting Point 1080F (583C) (approx.)
Bond Strength 3,787 psi on low carbon steel (63.6 Mpa)

4,458 psi on aluminum (29.3 MPa)
Coating Texture (as sprayed) Variable *, ** (see next page)
Texture (as machined) 40-80 (microinches aa)*, **
Hardness - macrohardness R15T 84 (RB 72 converted)

- microhardness 126 DPH300
Coating Density 2.41 gm/cc (89%)***
2
Coating Weight 0.013 lbs/ft /mil(0.25 kg/m2/0.1 mm)
Shrink 0.0068 in/in (cm/cm)
Porosity Less than 2 percent
Spraying:
Spray Rate 6 lbs/hr/100 amps (2.75 kg/hr/100 amps)
2 2
Coverage (wire consumption) 0.30 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)
Grit Blasting
Aluminum or magnesium substrates should be grit blasted with a blaster, using a pressure which does not
allow for entrapment of the grit in the substrate. Chilled iron or steel grit is recommended. If aluminum oxide
grit is used do not use blast pressures over 30 psig. When blasting hold the blast gun at a slight angle instead
of 90. This will eliminate straight bounce back interfering with the blast stream and it will minimize grit
entrapment. Both these recommendations minimize dust entrapment in the substrate, which could reduce
coating bond strengths.
* Depends on nozzle cap and air pressure and atomizing gas type.
** 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
Spraying Procedure
These are starting parameters only. Optimum parameters will vary depending on application, utilities,
Coating Type
Standard ArcJet Standard ArcJet Standard ArcJet
8830\35 8830\35 8850 8850 9000 9000
Atomizing Air Pressure
c c c c c c
Primary 60 50 60-70 60 60-70 60
Secondary -- 40 -- 60 -- 60
Contact Tip 450044 450044 450491 450491 450044 450044
Nozzle Cap Green * Green 451071 Green Green
Nozzle/Positioner (=cross) Long ** Long Long Long Long
a
Arc Load Volts 28-30 29-31 29-31 29-31 29-31 29-31
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 4-5 2-4 2-4 2-4 2-4 2-4
Coating Thickness/Pass-mils 3-5 3-5 3-5 3-5 3-5 3-5
Coating Texture-microinches aa 200-350 150-200 200-350 150-200 200-350 150-200
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 300F
can improve bond and deposit efficiency.
NOTE: Standard air caps and positioners can be used in 8830, 8850, or 9000 systems.
* P/N 450729 8830/8835 Arc Jet Air Cap

** P/N 620074 Arc Jet Modified Short Cross (8830 & 8835)
a
When using power lead extensions other than the normal 12 foot furnished, the voltage must be increased by
approximately 3.4volts 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.
environment, spray rate and equipment.
Page 3
Finishing:
Finish coating by machining. Machining can be done with either high speed or carbide tools. Excellent finishes
have been produced without lubricant using a "D" shape tungsten carbide tool bit, with the work rotating at 185
surface feet per minute, a traverse of 0.025" per revolution, and infeed of 0.002". Wet machining, using a
lubricant suitable for aluminum, also produces satisfactory results.
Hazards:
Observe normal spraying practices, respiratory protection and proper air flow patterns advised. For general spray
practices, see AWS Publications AWS C2.1-73, "Recommended Safe Practices for Thermal Spraying," and AWS
TSS-85, "Thermal Spraying, Practice, Theory and Application." Thermal spraying is a completely safe process
when performed in accordance with proper safety measures. Become familiar with local safety regulations before
starting spray operations. DO NOT operate your spraying 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.
DISREGARDING THESE INSTRUCTIONS MAY BE DANGEROUS TO YOUR HEALTH.
The Information provided herein is believed to be accurate and reliable; however, results may vary 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.
Copyright 2000 Praxair Technology, Inc. All rights reserved www.praxair.com/thermalspray

psti-info@praxair.com Telephone: 603-224-9585
Telephone: 1-317-240-2650 Fax: 603-225-4342
Fax: 1-317-240-2596 TAFA is constantly improving its products, therefore specifications are
subject to change without notice
Praxair, the Flowing Airstream design and Making our planet more
productive are trademarks or registered trademarks of Praxair TAFA Incorporated is a Praxair Surface Technologies company.
Technology, Inc. in the United States and/or other countries.
Other trademarks used herein are trademarks or registered

trademarks of their respective owners.
Printed in the United States of America 05-2000
Page 4
File: 1.9.1.2-01S
Issue: 011111
Supercedes: M11103
Praxair and TAFA Arc Spray Silicon Aluminum Wire - 01S
Material Review:
Made exclusively for arc spraying, aluminum silicon alloy wire produces coatings which are slightly less corrosion-
resistant than with an aluminum coating. Advantages achieved with the coating are a harder surface, does not
gall like aluminum; more dense and finer texture and faster spray adhesion.
Recently successful results have been achieved with the use of silicon aluminum as a mold back-up in the
electroform process and repair of cast Kirksite molds.
Arc Spray 01S, Silicon Aluminum Wire, can be sprayed with any Praxair and TAFA Arc Spray gun.
Arc Spray 01S Silicon Aluminum Wire meets Department of Defense Specification MIL-W-6712C, Table II, Silicon
Aluminum and Garrett FP5045.
TAFA certified wires
Application Review:
Recommended for any aluminum build-up on worn machine parts, for machine element work, for altering the
shape of aluminum castings in most model work, or for repairing blow-holes in aluminum patterns.
Praxair and TAFA 01S produces coatings which are harder and slightly denser than coatings produced by Praxair
and TAFA 01T pure aluminum. Sprayed coatings of Praxair and TAFA 01S are currently being used for the
repair of worn parts of jet engines, and the restoration of dimension to jet engine parts which were mis-machined
in manufacture.
Excellent as a filler metal for the brazing of the higher melting aluminum alloys, 2S, 3S and numbers 1 and 2
brazing sheet.
Silicon Aluminum 01S is applicable to the spraying of glass for a heat-reflective or light-reflective surface.
Composition
Aluminum 95 Percent
Silicon 5 Percent
Bond Strength 7,890 psi on low carbon steel (51.0 MPa)
4,250 psi on aluminum (29.3 MPa)
Coating Texture (as sprayed) Variable *, ** (see next page)
Texture (as machined) 40-80 (microinches aa)*, **
Hardness 95 Rh
2
Coating Weight 0.013 lbs/ft /mil
Grit Blasting
Aluminum or magnesium substrates should be blasted with a pressure which does not allow an entrapment
of the grit in the substrate. Chilled iron grit is recommended. Do not use aluminum oxide blast pressures
over 30 psig. Both these recommendations minimize dust entrapment in the substrate which could reduce
coating bond strengths.
Spraying:
Coverage (wire consumption) 2 2
0.30 oz/ft /0.001" (0.37 kg/m /100 microns)
Length of wire per lb. 282 ft (1/16"), 176 ft (2 mm)
* Depends on nozzle cap and air pressure and atomizing gas type.
** 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
Spraying Procedure
Coating Type
8830\35 8830\35 8850 8850 9000 9000
Atomizing Air Pressure
c c c c c c
Primary 60 50 50 50 50 50
Secondary -- 40 -- 50 -- 50
Contact Tip 450044 450044 450491 450491 450044 450044
Nozzle Cap Green * Green 451071 Green Green
Nozzle/Positioner (=cross) Long ** Long Long Long Long
a
Arc Load Volts 28-30 29-31 29-31 29-31 29-31 29-31
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 4-5 2-4 2-4 2-4 2-4 2-4
* P/N 450729 8830/8835 Arc Jet Air Cap

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 300F can improve
bond and deposit efficiency.
a When using power lead extensions other than the normal 12 foot furnished, the voltage must be
increased by approximately 3.4volts 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
Finishing
Finish coating by machining. Machining can be done with either high speed or carbide tools. Excellent finishes
have been produced without lubricant using a "D" shape tungsten carbide tool bit, with the work rotating at 185
surface feet per minute, a traverse of 0.025" per revolution, and infeed of 0.002". Wet machining, using a
lubricant suitable for aluminum, also produces satisfactory results.
Hazards

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
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 1000F.
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.
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.)
Wire Size 1/16" (1.6 mm), 2.0 mm
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
Spraying
2 2
Spray Pattern***** (approximate 8" standoff) Cross Nozzle/Positioner - 1" (2.5 cm)
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
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
will cause popping.
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
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.praxair.com/thermalspray
protection and proper air flow patterns advised. For psti-info@praxair.com
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.praxair.com/thermalspray
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
File: 1.9.1.2-02A
Issue: Q11121
Supercedes: M10310
Praxair and TAFA TAFALOY 02A

Zinc/Aluminum Wire
Material Review:
Made exclusively for arc spraying primarily as an anti-corrosion coating. Additional functions are for galvanizing
and general oxidation resistance. TAFALOY 02A is pure metal, and is not contaminated in the arc spray process.
TAFALOY 02A Zinc/Aluminum alloy wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Application Review:
Traditionally zinc or aluminum have been used for corrosion protection, both in atmospheric and marine
environments. For long term anti-corrosive applications, zinc must be covered with protective 5-8 mil layer of an
approved sealer in all but mild rural applications. Typically a phosphate primer is sprayed directly on a freshly
sprayed zinc surface followed by either a vinyl copolymer or a coal tar epoxy, the latter for severest environments.
TAFALOY 02A is an alloy of 85 percent zinc and 15 percent aluminum. The data included in this bulletin indicate
that it is superior to zinc or aluminum for some corrosion protection applications - combining the advantages of
both. Best performance can be obtained with 02A in atmospheric applications. In an ideal situation on a flat plate,
zinc does as well; however, this is not usually the case in the field where pockets and crevices exist and residual
moisture and contaminants remain for long periods of time. Under such circumstances the natural ability of the
02A to be more corrosion resistant in such an environment is a significant advantage. In addition, 02A resists
corrosion better after scratches and dings than pure zinc.
It is difficult to apply generalized rules of thumb, however, recognizing this, we make the following generalizations:
a) TAFALOY 02A should be considered for all atmospheric corrosion applications where zinc or aluminum
are being utilized.
b) For immersion in fresh water under high acidity use sealed aluminum only.
c) Generally, for rural atmospheres (humid and dry) and mild urban atmospheres, coatings without sealers
can be recommended. However, for all industrial, marine and submerged applications, a sealer must be
used. The purpose of the sealer is to fill the pores and prevent penetration of the environment to the
base. Prior to sealer application a wash primer must be used.
TAFALOY 02A, sprayed as a coating, is much purer than that achieved in the hot dip galvanizing process as it
does not pick up the iron that occurs with immersion in molten zinc. Arc sprayed 02A is competitive in cost with
plating or painting on all size elements but especially on larger elements when time and handling or location
problems impose restrictions on the use of the traditional plating process. On smaller parts, arc sprayed 02A
provides better protection when they can be finished by tumbling.
Composition:
Zinc 85 Percent
Aluminum 15 Percent

Wire Size 2.0 mm
Deposit Efficiency 70 Percent**
Melting Point 440C(approx.)
Bond Strength 3,680 psi blasted steel surface (25.4 MPa)

350-1000 psi blasted plastic surface(2.4-6.9 MPa)
Coating Texture Variable*** (see next page)
Hardness R15T 85 (RB 73) Converted from Knoop100

3
Coating Density 4.97 gm/cm (91%)****
2 2
Coating Weight 0.0484 lbs/ft /mil = .593 Kg/m /100 microns
Spraying:
Spray Rate 21 lbs/hr/100 amps = 9.5 Kg/hr/100 amps
2
Coverage (wire consumption) 0.8 oz/ft /mil (approx.)*
2
(.98 kg/m /100 microns)
Spray Pattern**** (approximate 8" standoff) Cross Nozzle/Positioner - 1 1/4" (3.2 cm)
vertical height x 2" (5 cm) width
Slot Nozzle/Positioner - 2 1/4" (5.7 cm)
Length of wire per lb 83 ft (2 mm)
* For grit blasted steel, depends on substrate material and deposit efficiency
** Depends on air pressure, standoff, nozzle cap and target size.
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
Spraying Procedures:
Coating Type
Normal ArcJet ArcJet 9000
8830/35 8830/35 9000
c c
Atomizing Air Pressure:Primary 60 50 50 60-75
Secondary --- 40 35 ---
Nozzle Cap Green * Green Green
Nozzle/Positioner Long C ** Long C Long C
(Cross=C;Slot=S)
a
Arc Load Volts 20-21 20-21 21-22 21-22
b
Amps 50-300 50-300 50-300 50-300
Standoff Inches 3-10 3-10 3-10 3-10
Coating Thickness/Pass-mils 2-10 2-10 2-10 2-10
Coating Texture-microinches Ra 200-350 100-200 100-200 200-350
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 300F can improve bond and deposit efficiency.
NOTE: Standard air caps and positioners can be used in 8830 or 9000 systems.
* P/N 450729 8830 Arc Jet Air Cap

--------------------------
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 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
c
Page 3
Finishing:
Most anti-corrosive coatings of sprayed zinc (as with aluminum) are put into service without additional machining.
Precautions:
Zinc fumes are toxic. TAFALOY 02A produces less fume than pure zinc. While spraying, all personnel should be
made aware of the need for complete respiratory protection.
Hazards:
A Material Safety Data Sheet will be sent with each purchase and updated as required.

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-02C
Issue: M11117
Supercedes: K10320
Praxair and TAFA Arc Spray Tin Alloy Wire - 02C
Material Review:
Made exclusively for arc spraying, this tin alloy attains the advantages of the low melting temperatures of tin with
the corrosion resistance of zinc.
Arc Spray 02C Tin-Zinc wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Application Review:
With the alloy's properties of tin, the coatings are solderable. As with zinc, the coating has a degree of oxidation
resistance. Used for capacitor end coatings and other related elements.
Composition:
Tin 60 Percent
Zinc 40 Percent

Wire Size 2 mm
Melting Point 590F (310C)
Bond Strength 2950 psi (20.4 MPa) blasted surface
Coating Texture Variable** (see next page)
Hardness R15T 0-6

2
Spraying:
Spray Rate 34 lbs/hr/100 Amps = (15.4 kg/hr/100 amps)
2 2
* Depends on air pressure, standoff, nozzle cap and target size.

rough with low psi.
*** Depends on atomizing air pressure
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/35 8830/35 8850 8850 9000 9000
c c c c c c
Atomizing Air Pressure:Primary 60 50 60-75 60 60-75 60
Secondary --- 40 --- 60 --- 60
Nozzle Cap Green * Green Green Green Green
Nozzle/Positioner (Cross=) Long ** Long Long Long Long
a
Arc Load Volts 21-23 21-23 22-24 22-24 22-24 22-24
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 3-10 3-10 3-10 3-10 3-10 3-10
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 300F can improve
* P/N 450729 8830/8835 Arc Jet Air Cap

*Diameter of wire
--------------------------
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 extension; i.e. add 3.4 volts to the recommended voltage setting for a
b
c
Page 3
Finishing:
Most coatings are used as sprayed.
Precaution:
Zinc fumes are toxic. While spraying, all personnel should be made aware of the need for complete respiratory
protection.
Hazards:
practices, see AWS Publications AWS C2.1-73, "Recommended Safe Practices for Thermal Spraying" and AWS
TSS-85, "Thermal Spraying, Practice, Theory and Application". Thermal spraying is a completely safe process

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-02T
Issue: M11117
Supercedes: K10320
Praxair and TAFA Arc Spray Tin Alloy Wire - 02T
Material Review:
Made exclusively for arc spraying, this tin alloy attains the advantages of the low melting temperatures of tin with
the corrosion resistance of zinc.
Arc Spray 02T Tin-Zinc wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Application Review:
With the alloy's properties of tin, the coatings are solderable. As with zinc, the coating has a degree of oxidation
resistance. Used for capacitor end coatings and other related elements. The Praxair and TAFA mold process
employs the use of tin-zinc to achieve fine detail requirements.
Composition:
Tin 80 Percent
Zinc 20 Percent

Wire Size 2 mm
Deposit Efficiency 45-85 Percent*
Hardness R15T 0-6
Coating Density 6.7 gm/cc*

2
Coefficient of Expansion 22.2 miro-in/in/F
Spraying:
Spray Rate 45 lbs/hr/100 Amps = (20.4 kg/hr/100 amps)
2 2
3
Density 0.26256 lbs/in

rough with low psi.
*** Higher air pressures, smaller wire (1/16), and lower amperage with red nozzle cap gives smallest
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/35 8830/35 8850 8850 9000 9000
c c c c c c
Secondary --- 40 60 --- 60
a
Arc Load Volts 21-23 21-23 22-24 22-24 22-24 22-24
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 3-10 3-10 3-10 3-10 3-10 3-10
Coating Texture-microinches Ra 150-250 100-200 150-250 100-200 150-250 100-200
popping.
* P/N 450729 8830/8835Arc Jet Air Cap

--------------------------
a
b
c
Page 3
Finishing:
Most coatings are put into service without additional treatment or machining.
Precaution:
protection.
Hazards:

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-02W
Issue: N10618
Supercedes: M11117
Praxair and TAFA Arc Spray Pure Tin Alloy Wire - 02W
Material Review:
Made exclusively for arc spraying, pure tin is a low melt material with excellent solderability, conductiveness, and
corrosion resistance.
Arc Spray Tin wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Arc Spray Tin wire meets Department of Defense Specification MIL-W-67l2C, Table II, Tin.
Application Review:
Tin wire is commonly used in electrical applications to produce solderable coatings for electrical connections and
as a very effective EMI/RFI shield. It is also extremely corrosion resistant to a variety of chemicals and solvents
and is used as a tank liner in some applications.
Composition:
Tin 99.8 Percent (min.)

Wire Size 2 mm
Hardness R15T 83-84 (RB 69-71) Converted from Knoop

2
Coefficient of Expansion 22.2 micro-in/in/F
Spraying:
Spray Rate 23 lbs/hr/100 amps = (10.5 kg/hr/100 amps)
2 2
Spray Pattern (approximate 8" standoff) Cross Nozzle/Positioner - 1 1/4" (3.2 cm)
3

rough with low psi.
Page 2
Spraying Procedure:
Coating Type
8830/35 8830/35 8850 8850 9000 9000
c c c c c c
Secondary --- 40 --- 60 --- 60
a
Arc Load Volts 21-23 21-23 22-24 22-24 22-24 22-24
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 3-10 3-10 3-10 3-10 3-10 3-10
popping.
* P/N 450729 8830/8835 Arc Jet Air Cap

--------------------------
a
b
c
Page 3
Finishing:
Most coatings are put into service without additional treatment or machining.
Precaution:
While spraying, all personnel should be made aware of the need for complete respiratory protection.
Hazards:
Observe normal spraying practices, respiratory protection and proper air flow patterns advised. See AWS
Publication AWS C2.1-73, "Recommended Safe Practices for Thermal Spraying" and AWS TSS-85, "Thermal
Spraying, Practice, Theory and Applications". Thermal spraying is a completely safe process when performed in
accordance with proper safety measures. Become familiar with local safety regulations before starting spray
operations. DO NOT operate your spraying equipment or use the spray material supplied before you have
thoroughly read the Praxair and TAFA Instruction Manual.
Page 4
File: 1.9.1.2-02Z
Issue: M11230
Supercedes: M10407
Praxair and TAFA Arc Spray Zinc Wire-02Z

Material Review:
Made exclusively for arc spraying. Its primary uses are EMI/RFI shielding, capacitor end spraying and protective
anti-corrosion coating for general oxidation resistance. Arc Spray 02Z Zinc is 99.99% pure, and is not
contaminated in the arc spray process.
Arc Spray 02Z Zinc wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Arc Spray 02Z Zinc wire meets Department of Defense Specification MIL-W-6712C, Table II, Zinc.
Application Review:
Traditional applications of zinc (along with aluminum) have been primarily for corrosion protection, both in the
atmosphere and in the marine environment. For long term anti-corrosive applications, zinc should be covered
with protective 5-8 mil layer of a suitable sealer in all but mild rural applications. Consult Praxair and TAFA for
specifications. Typically a phosphate primer is sprayed directly on a freshly sprayed zinc surface followed by
either a vinyl copolymer (colored or aluminum pigmented) or a coal tar epoxy, the latter for severest
environments.
Zinc, sprayed as a coating, is much more pure than that achieved in the hot dip galvanizing process as it does not
pick up the iron that occurs with immersion in molten zinc. Arc sprayed zinc is competitive in cost with plating or
painting on all size elements but especially on larger elements when time and handling or location problems
impose restrictions on the use of the traditional plating process; on smaller parts arc sprayed zinc provides better
protection when they can be sprayed and finished by tumbling.
With a poor resistance to acids, zinc is not recommended for use in environments with a pH range below 6 and is
much more resistant to corrosion with the use of hard water than with soft. A zinc coating has poor resistance in
any water at temperatures above 140F.
In addition, zinc is recommended as a primer for surfaces to be painted and for coating non-metallic matter for
electrical conductivity.
Arc sprayed zinc coatings are popular and effective EMI/RFI shield for plastic electronic housings. They have
higher dB ratings than conductive paints, higher bond strengths and do not flake or peel. Approximately 50
percent of the EMI/RFI coatings on the market are arc sprayed zinc.
Arc sprayed zinc is also used to spray large electronic Tempest rooms which house electronic gear. A special
grade of this material is also used widely in spraying capacitors.
The material can be soldered to. The solder material which is used successfully in England is Ersin--Multi-Core,
60/40 tin lead alloy 366 flux (0.064" dia.). This material can be purchased from Multi-Core Solders, Ltd., Hemel,
Hempstead, Hertz, England. Other sources are undoubtedly available.
Composition:
Zinc 99.99 min.
Copper 0.004 max.
Wire Size 1/16" (1.6 mm), 2.0 mm
Deposit Efficiency 70 Percent**
Bond Strength 1,224 psi blasted steel surface (8.4 MPa)

350-1000 psi blasted plastic surface (2.4-6.9 MPa)
Coating Texture Variable*** (see next page)
Hardness R15T 80-85 (RB 60-73 Converted)

3
Coating Density 6.36 gm/cm (91%)****
2 2
Coating Weight 0.54 oz/ft /mil = .66/Kg/m /100 microns
Coefficient of Expansion 22.2 micro-in/in/F = 331 micron/cm/C
Resistivity 8.2 Micro ohms/cm (N2 sprayed)

9.8 Micro ohms/cm (Air Sprayed)
Spraying:
Spray Rate 21 lbs/hr/100 amps = (9.53 Kg/hr/100 amps)

2 2
Coverage (wire consumption) 0.9 oz/ft /mil (approx.)* (1.10 kg/m /100 microns)
Spray Pattern***** (approximate 8" standoff) Cross Nozzle/Positioner - 1 1/4" (3.2 cm)
Length of wire per lb 106 ft (1/16"), 66 ft (2 mm)
* For grit blasted steel, depends on substrate material and deposit efficiency.
** Depends on air pressure, standoff, nozzle cap and target size.
rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/35 8830/35 8850 8850 9000 9000
c c c
Secondary --- 40 60 --- 60
a
Arc Load Volts 20-21 20-21 21-22 21-22 21-22 21-22
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 3-10 3-10 3-10 3-10 3-10 3-10
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 300F can improve
* P/N 450729 8830/8835 Arc Jet Air Cap

** P/N 620074 Arc Jet Modified Short Cross (8830 & 8835
--------------------------
a
b
c
Page 3
Finishing:
Most anti-corrosive coatings of sprayed zinc (as with aluminum) are put into service without additional machining.
See Praxair and TAFA Bulletins on electrical shielding for more details and for special procedures when coating
some plastics.
Precautions:
protection.
Hazards:
The dry collection of zinc, also must be done under controlled conditions because of the potential of fire hazards.
Metallized dust and fume overspray, if collected dry or allowed to accumulate in large batches, can become a fire
or explosion hazard. Consistent good housekeeping procedures should be adhered to. Do not allow large
accumulations of dry dust in the spray booths or in other uncontrolled areas. If dry collection is used, consult
Praxair and TAFA and other experts in the field relative to experience and recommendations.

www.praxair.com/thermalspray psti-info@praxair.com
Telephone: 603-224-9585
Telephone: 1-317-240-2650
Fax: 603-225-4342
Fax: 1-317-240-2596
Praxair, the Flowing Airstream design and Making our planet more subject to change without notice
productive are trademarks or registered trademarks of Praxair
TAFA Incorporated is a Praxair Surface Technologies company.

PagePrinted
4 in the United States of America 05-2000
File: 1.9.1.2-04T
Issue: M11117
Supercedes: K10320
Praxair and TAFA Arc Spray Babbitt Wire 04T
Material Review: The Praxair and TAFA Arc Spray system produces
an extremely dense Babbitt deposit, which has
proved highly successful as a bearing surface.
Made exclusively for arc spraying, Babbitt is a Coatings compare favorably relative to bearing loads
special high-grade tin based (lead free) Babbitt wire.
achieved with puddling techniques.
Particularly applicable in spraying the dense
coatings required for high speed and heavy duty With puddling techniques all the old material must
bearings. Arc Spray 04T Babbitt wire can be
be removed and the surfaces cleaned to receive the
sprayed with any Praxair and TAFA Arc Spray gun.
new material. However, with the Praxair and TAFA
Arc Spray system, the old bearing must only be
Arc Spray 04T Babbitt wire meets Department of
baked to remove all oil and grease, and the old
Defense Specification MIL-W-6712C, Table II,
surface is then cleaned with a lathe tool prior to
Babbitt (tin base). applying the new Praxair and TAFA Babbitt coating.
Thereby, also reducing the total cost of material
CAUTION: All Praxair and TAFA wires have been
applied.
optimized for arc spraying. Use of alternate wires
usually cause problems such as excessive tip wear,
In some cases, Praxair and TAFA has found the
spitting and feeding problems. We only recommend
best way to apply the Praxair and TAFA Babbitt
Praxair and TAFA certified wires. system is to first coat the machined old Babbitt with
Praxair and TAFA BondArc (0.003" - 0.005"). The
Application Review: BondArc gives a superior bond and leaves a coarse
substrate, which greatly improves the bonding of the
Recommended for application on heavy-duty or Babbitt. After BondArc, apply Babbitt to the required
high-speed bearings. thickness.
One of the conventional ways to apply Babbitt to

bearings is puddling. This is accomplished by
building appropriate dams around the area of the
bearing and then pouring molten Babbitt and
working it to an approximate shape.
A second method of applying Babbitt has been to

use a conventional oxygen gas metallizing gun to
spray a single Babbitt wire. This requires
considerable art and cannot be done successfully by
many operators.
BondArcis a registered trademark of TAFA Incorporated, Concord, N.H.

Composition (approx.)
Tin 90.0 percent
Antimony 7.0 percent
Copper 3.0 percent
Lead (Trace impurity only)

Wire Size 2.0 mm
Melting Point 695F(369C)(approx.)
Bond Strength 2,870 psi (19.8 MPa)
Microhardness R15T 32-35

2
Shrink Negligible
Spraying
Spray Rate 50 lbs/hr/100 amps
2 2
Length of wire per lb. 66 ft. (2 mm)
3
Note: When spraying Babbitt care should be taken to decrease the tension on the wire feed rollers.

rough with low psi.
diameter pattern.
Page 2
Coating Type
8830/35 8830/35 8850 8850 9000 9000
c c c c c c
Secondary--- 40 60 --- 60
a
Arc Load Volts 21-23 21-23 22-24 22-24 22-24 22-24
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 3-5 3-5 3-5 3-5 3-5 3-5
--------------------------
a
b
c
Using excessive voltage reduces quality of coating. Use of Praxair and TAFA's 75B Wire as a Bond
Voltage should be adjusted to give minimum noise Coat:
and smooth arc operation. Excessive voltage
causes larger particles and poor spray pattern. Too In most applications Praxair and TAFA's 75B
low a voltage will cause popping. BondArc wire eliminates the need for surface
roughening.
Be sure not to overheat substrate even if this means
stopping to allow cooling, use air jet cooling if The following section outlines steps to be followed
greater speed is required. Note that on some when using this material.
applications where preheating is tolerable,
preheating work to 300F can improve bond and Note again that the 75B coating does not self-bond
deposit efficiency. on many non-ferrous materials and normal surface
preparation must be used.
NOTE: Standard air caps and positioners can be
used in 8830, 8850 or 9000 systems. Clean the surface to a white virgin metal by grit
blasting, grinding or polishing clean surface with
* P/N 450729 8830/8835 Arc Jet Air Cap emery cloth.
** P/N 620074 Arc Jet Modified Short
Cross (8830 & 8835) It must be a clean white metal surface free of
grease, oil and hand prints.
DO NOT HANDLE AFTER THE SURFACE HAS

BEEN PREPARED.
Page 3
1. Use short nozzle/positioner and blue nozzle cap.
2. Set spray pressure air at 50-60 psig (do this while

air is "ON" or flowing). Copyright 2000 Praxair Technology, Inc. All rights reserved
3. Run at 150 amps at 30 load volts.
Telephone: 1-317-240-2650
4. Gun distance from work 3 to 4 inches. Fax: 1-317-240-2596
5. Move gun over surface uniformly to give productive are trademarks or registered trademarks of Praxair
coverage over complete surface. Technology, Inc. in the United States and/or other countries.

6. Continue buildup with selected material using trademarks of their respective owners.
50psig spray pressure on console (this 50 psig Printed in the United States of America 05-2000
is for general metallizing; for coarser coatings
decrease 5 psig; for finer coatings increase 5
to10 psig, depending on the finish required).
Finishing:
Finish machine by conventional techniques. Telephone: 603-224-9585
Hazards: Fax: 603-225-4342

Observe normal spraying practices, respiratory TAFA Incorporated is a Praxair Surface Technologies company.
protection and proper air flow patterns advised. For
general spray practices, see AWS Publications AWS
C2.1-73, "Recommended Safe Practices for Thermal
Spraying" and AWS TSS-85, "Thermal Spraying,
Practice, Theory and Application." Thermal spraying
is a completely safe process when performed in
accordance with proper safety measures. Become
familiar with local safety regulations before starting
spray operations. DO NOT operate your spraying
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.
DISREGARDING THESE INSTRUCTIONS MAY BE

DANGEROUS TO YOUR HEALTH.
The Information provided herein is believed to be

accurate and reliable; however, results may vary
with workpiece preparation and operator
technique. Praxair and TAFA warrants only that
the wires are free of defects in material and
or implied.
Page 4
File: 1.9.1.2-05T
Issue: T11220
Supercedes: M11117
Praxair and TAFA Arc Spray Copper Wire - 05T
Material Review:
Made exclusively for arc spraying equipment, it is essentially pure, copper wire.
Arc Spray 05T copper wire can be sprayed in any Praxair and TAFA Arc Spray gun.
Application Review:
Generally used for its electrical and thermal conductivity. Applications include the provision of conductive
surfaces or solderable connections on resistors, carbon brushes, discharge electrodes and earthing conductors
on railway carriage axles. It is used for EMI and static discharge screening on paper conveyors. Its softness
makes it useful for surfacing printing rollers.
Other non-electrical applications for copper range from purely decorative purposes to elements requiring
protective coating.
Composition (approx.):
Copper 98.0 min.
Tin Trace
Silicon Trace
Manganese Trace

Bond Strength 1450 psi (10 MPa) on blasted surface
Coating Texture Variable*,** (see next page)
Hardness 37 Rb
161 Knoop100
Coating Density 7.54 gm/cc (90%)*
Coating Weight 0.039 lbs/ft2/mil
Spraying:
Spray Rate 11 lbs/hr/100 amps (5 Kg/hr/100 amps)
Coverage (wire consumption) 0.9 oz/ft2/0.001" (1.10 kg/m2/100 micron)
Spray Pattern*** (approximate 8" standoff) Cross Nozzle/Positioner - 1" (2.5 cm)
Length of wire per lb 84 ft. (1/16")
* Depends on atomizing air pressure.

** 6" standoff, 40 psi - 8830, depends on nozzle cap, air pressure - fine with high psi, average with
medium psi, and rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
Standard ArcJet 8830/35 Standard 9000 ArcJet 9000
8830/35
Atomizing Air Pressure:Primary 45-60c 50 c 60c 60c
Secondary --- 40 --- 60
Nozzle/Positioner (Cross=) Long ** Long Long
Arc Load Voltsa 28-30 29-31 29-31 29-31
Ampsb 50-300 50-300 50-300 50-300
Coating Thickness/Pass-mils 3-5 5 3-5 5
Coating Texture-microinches aa 200-350 150-250 200-350 100-200
popping.
greater speed is required. Note that on some applications where preheating is tolerable, preheating work to 300F
* P/N 450729 8830/8835 Arc Jet Air Cap

--------------------------
a
b
c
Page 3
Copper oxidizes readily; especially when exposed to temperatures above 350F (177C). The following
procedure will minimize oxidation:
1. Maintain spray distance shown above.

2. Make quick even passes across the work.
3. Do not let the coating temperature exceed 300F (149C).
For continuous spraying, a moderate flow of cooling air on the surface is recommended.
Finishing:
Copper is usually finished by machining or grinding.
Precaution:
Copper fumes are toxic. While spraying all personnel should be made aware of the need for complete respiratory
protection.
Hazards:
you have thoroughly read the Instruction Manual.
References:
See International Copper Research Association Inc. index to INCRA Publications, 708 Third Ave., New York, NY
10017. Index consists of 311 publications on copper including such subjects as protective coatings, surface
reactions of copper, fundamental research on the corrosion of copper, development of patina finishes for copper,
etc.

Telephone: 1-317-240-2650 Fax: 603-225-4342
Page 4
File: 1.9.1.2-06C
Issue: M11117
Supercedes: K10320
Praxair and TAFA Arc Spray Nickel Chrome

Wire - 06C
Material Review:
Made exclusively for arc spraying. This material produces coatings that resist corrosive gases and oxidation
temperatures up to 1800F. A coating of this material can also be used to resist heat and prevent oxidation
scaling of conventional low alloy steels. These coatings have also been used as an oxygen barrier under sprayed
coatings of ceramic. The coating is machinable. This material can be sprayed with any Praxair and TAFA Arc
Spray gun.
Praxair and TAFA 06C meets the following specifications: PWA 1317D, Rolls Royce MSSR9507/27 and
SNECMA DMR33-079.
Application Review:
Praxair and TAFA 06C is used to produce oxidation and heat resistant coatings and oxidation resistant bond
coatings for ceramics. When applied 0.010" thick it will retard or prevent heat oxidation of carbon steels and low
alloy steels to temperatures of 1800F. At 0.005", coatings used as a bond coat for ceramics have been found to
retard or prevent heat oxidation of the base material. Thicknesses of 0.001" to 0.002" are adequate for bonding
ceramic coatings to an oxidation-resistant base material. The material has also been used as an excellent bond
coat with bond strengths considerably higher than stainless steels.
It has been found through experiments that corrosion can occur under ceramic coatings directly applied to iron
alloys, stainless steels and alloys of aluminum and nickel. Both salt and other chloride atmospheres accelerate
this corrosion phenomenon. Currently inadequate information is available to determine whether this corrosion
phenomenon may apply to other corrosive atmospheres as well when ceramic coatings are applied directly to a
metal substrate, which develops passive oxide films. It is felt that this corrosive condition comes about because
of the loss of protective oxide films during the grit blasting operation prior to ceramic coating. The corrosion can
be identified in some cases by observing the ceramic coating that has failed and noticing the characteristic red
iron oxide or white aluminum oxide. In the case of salt environments, it appears that some electrochemical
reactions are accelerated. It has been found in laboratory investigations that the corrosion is significantly inhibited
when the Praxair and TAFA 06C wire coat is used.
The procedure in this case is to apply 0.002" - 0.005" of the barrier coat with coatings on the thinner end of the
tolerance used where fine sprayed surface finishes are required and the thicker end when a coarse ceramic
powder is utilized.
Nickel 80 percent
Chromium 20 percent

Bond Strength 7320 psi (50.5 MPa)
Macrohardness 90 RB
Coating Density 7.1 gm/cc***

2
Finish, machined: Fair

ground: Good
Spraying:
Spray Rate 11 lbs/hr/100 amps (5 kg/hr/100 amps)
2 2
Coverage (wire consumption) 0.8 oz/ft /0.001" (0.98 kg/m /micron)

rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
Standard Standard 8850 Standard 9000
8830/35
c c c
Atomizing Air Pressure:Primary 50 60 60
Secondary --- 60 ---
Nozzle Cap Blue Green Green
Nozzle/Positioner (Cross=C; Slot=S) Short C Long C Long C
a
Arc Load Volts 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300
Coating Thickness/Pass-mils 5 5 5
Coating Texture-microinches aa 200-350 200-300 200-300
popping.
--------------------------
a
b
c
Page 3
Finishing:
Nickel Chrome is usually finished by machining or grinding with machining giving a fair finish and grinding giving a
good finish.
Hazards:
Observe normal spraying practices, respiratory protection and proper air flow pattern advised. For general spray
practices, see AWS Publications AWS C2.1-73, "Recommended Safe Practices For Thermal Spraying" and AWS

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-06T
Issue: M11231
Supercedes: K10405
Praxair and TAFA Arc Spray Nickel Wire - 06T
Material Review:
Made exclusively for arc spraying as an essentially pure nickel wire (the impurities constitute less than 1 percent
of the material). Used for its corrosion-resistance properties and high melting point temperature, when machined,
yields a fair finish. Praxair and TAFA produces coatings that are dense and readily machinable for salvage and
buildup of nickel and nickel alloy parts.
Arc Spray 06T Nickel Wire can be sprayed withany Praxair and TAFA Arc Spray gun.
Arc Spray 06T Nickel Wire meets Department of Defense Specification MIL-W-6712C, Table II, Nickel.
CAUTION : All Praxair and TAFA wires have been optimized for arc spraying. Use of alternate wires usually
Application Review:
Used primarily for machine element work where conditions involve higher temperatures and necessitate corrosion
protection. Examples include resurfaced pump plungers, impellers, rams, pump sleeves, shafts, seal rings,
casings, valve plugs, and wedges. Also used to attach graphite to current lugs an some nuclear industry anodes.
Nickel 99.0 min.
Carbon Trace
Sulphur Trace
Iron Trace
Silicon Trace
Cobalt Trace
Copper Trace

Bond Strength Good
Hardness 58 Rb

2
Spraying:
Spray Rate 10 lbs/hr/100 amps (4.5 kg/hr/100amps)
2 2
Spray Pattern***** (approximate 8" standoff) Cross Nozzle/Positioner - 1" (2.5 cm)
Surface Preparation:
The substrate may be prepared by any standard method. Use of Praxair and TAFA 75B bond coat is
recommended.

rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
These are starting parameters only. Optimum parameters will vary depending on application, utilities, environment,
spray rate and equipment.
Coating Type
8830/35 8830/35 8850 8850 9000 9000
c c c c c c
Atomizing Air Pressure:Primary 50 50 60 60 60 60
Secondary --- 40 --- 60 --- 60
Nozzle Cap Blue * Green Green Green Green
Nozzle/Positioner (Cross=) Short ** Long Long Long Long
a
Arc Load Volts 29-30 29-30 30-32 30-32 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 5-7 5-7 5-7 5-7 5-7 5-7
Coating Thickness/Pass-mils 5 5 5 5 5 5
popping.
* P/N 450729 8830/8835 Arc Jet Air Cap

--------------------------
a
b
c
Page 3
Finishing:
Nickel is usually finished by machining or grinding. Conventional tool shapes are used and light cuts and high
work speeds give best results.
Hazards:

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-10T
Issue: O10504
Supercedes: L10906
Praxair and TAFA Arc Spray Aluminum Bronze - 10T
Material Review:
CAUTION: All Praxair and TAFA wires have been
optimized for arc spraying. Use of alternate wires
Made exclusively for arc spraying. Characteristics
usually cause problems such as excessive tip
of the coating are very high bond strengths and its
wear, spitting and feed problems. We only
ability to produce a dense, wear resistant surface,
recommend Praxair and TAFA certified wires.
advantageous for machine element work. The use
of 1/16 wire with this material has the added
advantage of fume reduction during spraying. The Application Review:
prealloyed wire produces superior bond coats that
are dense, resistant to corrosion, mechanical and Recommended for all general metallizing work with
thermal shock. The material is very suitable as a bronze. This material is an extremely effective
one-coat system and machines very easily to a bond coat where surface preparation may be less
finish of 5 micro inches. The unusual self-bonding than optimum; for example, on cast iron or steel. It
ability of the alloy is attributed to the exceptionally is also used as a coating in its own right and has
high temperatures the alloy reaches, and which on the highest corrosion resistance and maximum
impact with the base material, diffuses to form a wear resistance of the arc spray bronzes. Major
metallurgical bond. One of the major problems in uses, in addition to bond coats, are for bearings in
achieving high quality, well-bonded coatings in any the steel industry and for reclaiming alumi-
thermal spray process is the expensive and num/bronze components, including propeller shafts
extensive preparation of the substrate. Aluminum for operation in sea water. Praxair and TAFA 10T
bronze eliminates the problem. The coating, aluminum bronze can be machined but, again,
through extensive testing, has been found to be far grinding will give a better surface.
superior to that produced by most materials, not
only in bond strength, but also in sharp edge and Arc spray coats from 0.004" (0.01 mm) to 0.006"
impact loading. Aluminum bronze is self-bonding (0.015 mm) can be readily applied in one pass.
to a broad range of smooth metal surfaces Thicker coatings up to 1/4 inch (6.3 mm) have
including annealed or hardened carbon steels, been applied by continuous spraying. Thus, in
hardened alloy steels, stainless steels, cast iron, some cases, 10T can be used as a one-coat
and copper based alloys. It is highly system. Coatings can be machined to a medium
recommended as the bond coat of choice for finish with high speed tools or ground to smooth
copper based alloys, as the nickel aluminum bond finish with aluminum oxide or silicon carbide
coats do not bond well to copper substrates. The wheels. It can be sprayed directly on a chemically
fact that the high performance characteristics are clean surface without conventional blasting, turning
obtained only with the wire arc spray process is or roughening, thereby eliminating the need for
attributed to the higher temperatures achieved--arc expensive preparation equipment and the
temperatures in the range of 7000-12,000F-- associated labor and quality control.
which produce superheated particles.
Arc Spray 10T aluminum bronze wire can be

sprayed with any Praxair and TAFA Arc Spray gun.
Composition
Copper Balance
Aluminum 7.0 percent
Iron 0.5 percent

Bond Strength 6066 psi (41.8 MPa) clean surface

6740 psi (46.5 Mpa) blasted surface
Coating Texture (as sprayed) Variable*
Texture (as machined) 30-100 Microinches aa **
Hardness 55-60 Rb
144 (Knoop100)
Coating Density 6.3 gm/cc**
Coating Weight 0.033 lbs/ft2/mil.
Impact, Sharp Edge & Bend Resistance Excellent
Spraying
Coverage (wire consumption) 0.9 oz/ft2/0.001" (1.10 kg/m2/100 microns)
Spray Pattern*** (approximate 8" standoff) Cross Nozzle/Positioner - 1" (2.5 cm)
Length of wire per lb. 100 ft. (1/16"), 62.5 ft (2 mm)
______________________________
* 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.
diameter pattern.
Page 2
Coating Type
Normal Arc Jet Arc Jet 9000 9000
8830/8835 8830/8835
Atomizing Air Pressure:Primary 45-60c 50 60 65-75c
Secondary --- 40 60 ---
Nozzle/Positioner (Cross=C; Slot=S) Long C ** Long C Long C
Arc Load Voltsa 28-30 29-31 29-31 29-31
Ampsb 50-300 50-300 50-300 50-300
Coating Thickness/Pass-mils 3-5 5 5 3-5
Using excessive voltage reduces quality of coating. Finishing:

Voltage should be adjusted to give minimum noise
and smooth arc operation. Excessive voltage Praxair and TAFA 10T coatings can be machined
causes larger particles and poor spray pattern. or ground to achieve a desired finish. Excellent
Too low a voltage will cause popping. finishes have been obtained on coatings of Praxair
and TAFA 10T using tungsten carbide tool bits with
Be sure not to overheat substrate even if this surface feet per minute, and a traverse of 0.0025"
means stopping to allow cooling, use air jet cooling per revolution. Best results are obtained with cuts
if greater speed is required. Note that on some of 0.010".
applications where preheating is tolerable,
preheating work to 300F can improve bond and Hazards:
deposit efficiency.
Observe normal spraying practices, respiratory
NOTE: Standard air caps and positioners can be protection and proper air flow patterns advised.
used in 8830 or 9000 systems. For general spray practices, see AWS Publications
AWS C2.1-73, "Recommended Safe Practices for
* P/N 450729 8830 Arc Jet Air Cap Thermal Spraying" and AWS TSS-85, "Thermal
** P/N 620074 Arc Jet Modified Short Cross Spraying, Practice, Theory and Application."
(8830 & 9000) Thermal spraying is a completely safe process
when performed in accordance with proper safety
measures. Become familiar with local safety
_______________________ regulations before starting spray operations.
DO NOT operate your spraying equipment or use
the spray material supplied before you have
thoroughly read the Praxair and TAFA Instruction
Manual.
a When using power lead extensions other than the
normal 12 foot furnished, the voltage must be
increased by approximately 3.4 volts per A Material Safety Data Sheet will be sent with each
initial purchase and updated as required.
50 foot of extension; i.e., add 3.4 volts to the
recommended voltage setting for a given wire if the DISREGARDING THESE INSTRUCTIONS MAY
extension is increased to a 50 foot length. BE DANGEROUS TO YOUR HEALTH.
b Can vary between 50-300 depending on size of The Information provided herein is believed to
workpiece and traverse speed.
be accurate and reliable; however, results may
c For finer finish, raise air pressure at point of finish. vary with workpiece preparation and operator
technique. Praxair and TAFA warrants only
that the wires are free of defects in material and
or implied.
Page 3

Telephone: 1-317-240-2650
Fax: 1-317-240-2596
Telephone: 603-224-9585
Fax: 603-225-4342
Page 4
File: 1.9.1.2-11T
Issue: 011111
Supercedes: L10506
Nickel Aluminum Bronze Arc Spray Wire - 11T
Material Review:
This wire produces dense, wear resistant coatings with very high bond strengths suitable for machine elements.
Nickel is included to increase the hardness of the coating and resist mechanical and thermal shock. Harder than
Praxair and TAFA's 10T, it is an excellent choice for resisting cavitation. Suitable as a one coat system, coatings
of 11T will machine to a finish under 30 microinches. The high arc temperature--ranging between 7,000 and
12,000F--superheats the sprayed droplets, yielding superior bonding, density and performance. The coating
bonds well to a broad range of smooth metal surfaces including annealed or hardened carbon steels, hardened
alloy steels, stainless steels, cast iron, and copper based alloys.
All Praxair and TAFA arc spray guns are capable of spraying 11T.
CAUTION: All Praxair and TAFA wires have been optimized for arc spraying. Use of alternate wires may cause
problems such as excessive tip wear, spitting and feeding problems. Please use only Praxair and TAFA certified
wires.
Application Review:
With cavitation, wear and high corrosion resistance among its valued properties, 11T can be used in saltwater
pumps at power generating plants and other marine environments. Natural gas compressor pistons and cylinder
liners are presently being sprayed with 11T because of its increased wear resistance. Certain tools are coated
with 11T where explosion hazards exist because 10T and 11T have little tendency to spark when struck.
Typical Composition:
Copper 81.5%
Aluminum 9%
Nickel 4%
Iron 4%
Manganese 1.5%

Length of 1/16" wire per lb (kg) 116 ft (35.4 m)

1
Deposit Efficiency 70 Percent
Bond Strength 6250 psi (43 MPa) (clean surface)

9000 psi (62.1 MPa) (blasted surface)
2
Texture (as sprayed) Variable (see next page)
Macrohardness 8015T
170 DPH300
3
Bulkwire Density 0.049 lbs/ft (7.8 gm/cc)
2 2
Coating Weight 0.033 lbs/ft /mil (0.66 Kg/m /0.1 mm)
Shrink 0.0055 in/in (.0139 cm/cm)
Impact, Sharp Edge and Bend Resistance Excellent
Spraying:
2 2
Coverage (wire Consumption) 0.9 oz/ft /0.001" (1.10 kg/m /100 microns)
3
Spray Pattern ArcJet with 50-60 psi air pressure and 3" standoff
distance produce the smallest spray pattern
1
Depends on air pressure, standoff distance, nozzle cap and target size.
2
Depends on air pressure - fine with high psi, average with medium psi, and rough with low psi
3
Depends on atomizing air pressure and the use of ArcJet.
Page 2
Spraying Procedure:
Coating Type
Normal ArcJet Normal ArcJet Normal ArcJet
8830/35 8830/35 8850 8850 9000 9000
4 4
Atomizing Air Pressure:Primary 50 50 60 60-75 60 60-75
Secondary --- 40 --- 60 --- 60
5
Arc Load Volts 29-31 29-31 30-33 30-33 29-31 29-31
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 3-4 3-4 3-4 3-4 3-4 3-4
Coating Thickness/Pass-mils 3-5 5 3-5 5 3-5 5
* P/N 450729 8830 ArcJet Air Cap

** P/N 620074 ArcJet Modified Short Cross
Using excessive voltage reduces the quality of the coating. Voltage should be adjusted to give minimum noise and
cause popping.
Be sure not to overheat the substrate even if this means stopping to allow cooling. Use air jet cooling if greater
speed is required. On applications where preheating is tolerable, preheating to 300F can improve bond strength
and deposit efficiency.
--------------------------
4
5
Power lead extensions longer than 12 feet require additional voltage. Add 3.4 volts to the recommended
setting for a given wire for every additional 50 feet of cable.
6
Can vary between 50-300 depending on size of the part and traverse speed.
Page 3
Finishing:
Machining will give a good finish. Typical conditions when using steel tool bits: "roughing" cuts range between
0.010 and 0.020" (.254 mm - .508 mm) while finishing cuts range between 0.005" to 0.008" (.127 mm -.203 mm).
Typical conditions when using carbide inserts are: roughing speed, 175 ft/min (53 m/min) with a feed of 0.011
in/rev (0.3 mm/rev); finishing speed: 125 ft/min (38 m/min) and a feed of 0.011 in/rev (0.28 mm/rev). These are
only guidelines that will vary depending upon the part size and shape, coating thickness and desired quality.
Hazards:
you have thoroughly read the Praxair and TAFA Instruction Manual. DISREGARDING THESE INSTRUCTIONS
IS DANGEROUS TO YOUR HEALTH.

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-13T
Issue: 011020
Supercedes: K10320
PRAXAIR AND TAFA Molybdenum (Mo) - 13T
Material Review:
Molybdenum wire has not normally been sprayed with arc spray. Up until now, with inert, reducing or oxidizing
atomizing gas the arc spray coating could probably be made equivalent to gas coatings with the attendant
advantages of arc. Praxair and TAFA applications engineers have developed a molybdenum wire and
parameters that meet or exceed aircraft and commercial specifications.
Arc Spray 13T, Molybdenum wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Arc Spray 13T Molybdenum wire meets the following specifications: PWA 36913 For PWA 271-13 Rev D, Rolls
Royce MSSR9507/19 and Garrett FP5045 Type 1.
CAUTION: All Praxair and TAFA wireshave been optimized for arc spraying. Use ofalternate wires usually cause
problems such asexcessive tip wear, spitting and feedingproblems. We only recommend Praxair and
Application Review:
Arc sprayed, molybdenum exhibits excellent adhesion to steels and is used as a bond coat where other methods
of preparation are impossible or undesirable. Coating hardness can be controlled over a wide range by varying
air pressure and spray distance. Coatings exhibit good bearing properties and high resistance to galling, scuffing
and "pick-up" as well as good wear and abrasion resistance. Molybdenum is not recommended for use above
400C (752F).
Composition:
Molybdenum 99+%

Wire Size 1/16" (1.6 mm) and 2 mm
Melting Point Approx. 2500C (4532F)
Bond Strength 7844 psi
Hardness Rc 14-36
Coating Density 8.86-9.84 gm/cc***

2
Coating Weight 0.047 lb/ft /mil
Adhesion Up to 5500 psi (37.9 MPa) when sprayed under the

correct conditions, Molybdenum is self bonding to
ferrous and aluminum based alloy. This bond is
normally higher than the cohesive strength of the
deposit, therefore, when tested to destruction
rupture occurs within the deposit.
Spraying:
Spray Rate 10 lb/hr/100 amps
2 2
Coverage (wire consumption) 1.13 oz/ft /0.001 in (1.38 kg/m /100 microns)
Spray Pattern(approximate 8" standoff) Cross Nozzle/Positioner - 1 in (2.5 cm)

vertical height x 1-3/4 in (4.4 cm) width
Slot Nozzle/Positioner - 2 in (5 cm)
vertical height x 1 in (2.5 cm) width
Length of wire per lb 70 ft.
* Depends on nozzle cap and air pressure and atomizing gas type
rough with low psi.
**** Higher air pressures, smaller wire (1/16"), and lower amperage with a green nozzle cap gives smallest
diameter pattern.
Page 2
Spraying Procedure
Coating Type
Normal ArcJet Arc Jet 9000 9000
8830/35 8830/35
c c c c
Atomizing Air Pressure:Primary 50 50 60 60
c c
Secondary --- 40 60 ---
Nozzle Cap Blue * Green Green
Nozzle/Positioner (Cross=C; Slot=S) Short C ** Long C Long C
a
Arc Load Volts 33-35 33-35 33-35 33-35
b
Amps 100-200 100-200 100-200 100-200
Coating Thickness/Pass-mils 5 5 5 5
***Tips - Always use P/N450044 for 13T
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.
greater speed is required. Note that on some applications where preheating is tolerable, preheating work
to 300F can improve bond and deposit efficiency.
NOTE 1: Standard air caps and positioners can be used in 8830 or 9000 systems.

*** P/N 450044 Tips for Aluminum
NOTE 2: In setting up the 8830 or 8835 - Standard or Arc Jet, push the contact tubes forward until the back end of
them with the power leads are flush with the alignment housing. This will maximize the bond strength, optimize the
microstructure and give consistent results.
a
by approximately 3.4 volts per 50 ft. 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
c
Page 3
Finishing:
Sprayed Molybdenum coatings must be finished by grinding. Where used as a bond coat no further treatment is
required prior to the application of subsequent coatings. The following grinding parameters are recommended:
Speeds - Wheel, SFPM: 6000

m/s: 0.29
Work, m/s: 0.37
Traverse Feed - Roughing: 1/3 wheel width per revolution

Finishing: 1/7 wheel width per revolution
These are starting recommendations. Diamond wheels remove stock with less wear, but will not produce better
finishes for equivalent grain size.
Service Limitations:
Although Molybdenum has a very high melting point, one of its oxides is volatile at a comparatively low
temperature. Catastrophic oxidation of Molybdenum may occur in oxidizing atmospheres at elevated
temperatures and even where the atmosphere is not oxidizing.
Hazards:
Observe normal spraying practices, respiratory protection and proper air flow pattern advised. See AWS
Publication AWS C2.1-73, "Recommended Safe Practices for Thermal Spraying" on general spray practices and
AWS TSS-85, "Thermal Spraying, Practice, Theory and Application". Thermal spraying is a completely safe
process when performed in accordance with proper safety measures. Become familiar with local safety
regulations before starting spray operations. DO NOT operate your spraying equipment or use the spray material
supplied before you have thoroughly read the Praxair and TAFA Instruction Manual.
Page 4

Telephone: 603-224-9585
Telephone: 1-317-240-2650
Fax: 603-225-4342
Fax: 1-317-240-2596

Page 5
File: 1.9.1.2-14T
Issue: 011111
Supercedes: K10908
Praxair and TAFA Inert Arc Spray Titanium

Wire -14T
Material Review:
Made exclusively for inert gas arc spraying, Praxair and TAFA 14T is a chemically pure titanium material used
where chemical inertness and/or light weight is required.
Praxair and TAFA 14T Titanium is especially suitable for spraying in inert atmospheres, such as argon, so as to
preclude the possibility of extreme oxidation. Conforms to ASTM B348/Grade 1 and ASTM F67-89/Grade 1
specifications.
Inert gas arc spray 14T Titanium can be sprayed with any Praxair and TAFA Arc Spray gun including the Models
8830 and 8835. Spraying in totally inert chambers may require special seals and fittings.
All Praxair and TAFA wires have been optimized for arc spraying. Use of alternate wires usually cause problems
such as excessive tip wear, spitting and feeding problems. We only recommend Praxair and TAFA certified
wires.
Material Review:
A particularly suitable application is in the thermal spray coating of human (and animal) bone implants and repair
parts such as pins, joints or sockets. In this application, a coarse coating is desirable to enhance bone growth
into the coating surface. Additional applications exist in the aerospace industry for metal matrix composites.
Composition:
Titanium 99.8%

Bond Strength >8,000 psi (39.3 MPa) blasted surface
Coating Texture Selectable**
Hardness 70-80 Rb

2
Spraying (inert chamber with argon):

2 2
Spray Pattern****(approximate 8" standoff) Cross Nozzle/Positioner - 1" (2.5 cm)

vertical height x 1-3/4" (4.4 cm) width

** Depends on air pressure - fine with high psi, average with medium psi, and rough with low psi.
*** Depends on atomizing air pressure, standoff, amperage.
**** Higher air pressures, smaller wire (1/16"), and lower amperage with red nozzle cap gives smallest
diameter pattern.
Page 2
Spraying Procedure: Using 8830 or 8835 with inert gas (argon) enclosures
Coating Typea
Normal/Inert Chamber
Atomizing Air Pressure: 60 psi
Nozzle Cap 1/2" Blue Cap
Nozzle/Positioner (Cross=C; Slot=S) Short C
b
Arc Load Volts 32-35
Amps 150-350c
Standoff Inches (cm) 4-6 in (10-15)
Coating Thickness/Pass-mils (microns) 5-15 (125-375)
Coating Texture-microinches aa Medium 200-350
popping.
required.
--------------------------
a See last page of this bulletin for general guidelines.
b 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.
c Can vary between 150-350 depending on size of workpiece and traverse speed.
Page 3
Finishing:
Deposit thicknesses of up to 0.080 may be finished by turning, but can be machined or ground. In many
applications, including bone implants, finishing is often not necessary.
General Spraying Notes:
The following are general notes only and are not intended to be recommendations for any particular application.
When using this special Praxair and TAFA wire it is expected that the user will have to do a reasonable amount of
experimentation to get optimum spray conditions for the particular application. The following notes represent
guidelines for most coating parameter development work.
For finer finish, raise the air pressure.
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.
Amperage can vary between 150-350 depending on size of workpiece and traverse speed. Higher amps also mean
higher deposition rates.
Hazards:
NOTE: Spraying reactive materials like Titanium and spraying in an inert chamber can produce fire and explosion
hazards - obtain professional advise before attempting to spray such material .

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-30S
Issue: 011111
Supercedes: N10817
Praxair and TAFA Arc Spray Silver Alloy Wire-30S
Material Review:
Made exclusively for arc spraying, Praxair and TAFA 30S wire produces a coating that is easily machined to close
tolerances and provides good rubbing wear characteristics. For these reasons, 30S wire is frequently used as a
coating for stationary seals in aircraft engines such as the General Electric CF6 engine series.
The Praxair and TAFA 30S wire works best when used with Praxair and TAFA 75B BondArc as a bond coat.
This two step system produces a coating that is superior to other application methods in both bond strength and
wear resistance. 30S coatings can be heat treated at 850-900F (454-482C) for two hours as per GE
specifications to create a more homogenous coating.
Praxair and TAFA 30S arc spray wire can be sprayed with any Praxair and TAFA arc spray gun.
Praxair and TAFA 30S arc spray wire meets the following specifications: General Electric material specification
(chemistry only) B20A4, GE Standard Practices Manual 70-49-44 (this manual section is an alternate to section
70-49-17), FAA RDE # 00-630.
causes problems such as excessive tip wear, spitting and feeding problems. We only recommend Praxair and
Composition: (Typical)
Copper 37.0-39.0 percent
Zinc 30.0-34.0 percent
Silver 29.0-31.0 percent
Impurities (max) 0.15 percent

Wire Size 1/16 in (1.6 mm)
Bond Strength Tensile 7000 psi blasted (48 MPa)
Coating Texture (as sprayed) Variable**
Hardness 86-94 HRE (After heat treat to GE standard practices

manual #70-49-17 340-018 item 5.) 71-77 HRB as
sprayed
2
Coefficient of Thermal Expansion 125 micro-in/in F (1000F) (537C)
Spraying:
2 2
Coverage (wire consumption) 1.0 oz/ft /mil (1.2 kg/m /100 microns)
Spray Pattern****(approximate) Cross Nozzle/Positioner - 1 in (2.5 cm)

vertical height x 1.75 in (4.4 cm) width
Length of wire per lb 87 ft. (1/16 in)

** Depends on air pressure - fine with high psi, average with medium psi.
**** Higher air pressures, smaller wire (1/16), and lower amperage with Gold nozzle cap gives smallest
diameter
Page 2
Spraying Procedure:
Coating Type
8830/35 8830/35 8850 8850 9000 9000
c c c c c c
c c c
Secondary --- 40 --- 60 --- 60
a
Arc Load Volts 28-30 29-31 29-31 29-31 29-31 29-31
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 4-6 3 4-6 3 4-6 3
Coating Thickness/Pass-mils 3-5 5 3-5 5 3-5 5
popping.

NOTE 2: Use 75B BondArc parameters for bond coat.
NOTE 3: Preferred parameters are for ArcJet, 8830, 8835, 8850 and 9000 guns.
--------------------------
a
b
c
Page 3
Praxair and TAFA's 75B - Wire as a Bond Coat:
In most applications Praxair and TAFA's 75B BondArc wire reduces the need for surface roughening. the
following section outlines steps to be followed when using this material.
Note again that the 75B coating does not self-bond on many non-ferrous materials and normal surface
Clean the surface to a white virgin metal by grit blasting, grinding or polishing clean surface with emery cloth.
It must be clean white metal surface free of grease, oil and hand prints.
DO NOT HANDLE AFTER THE SURFACE HAS BEEN PREPARED.
1. Use long nozzle/Positioner and green nozzle cap.
2. Set spray pressure air at 40-50 psig (do this while air is "ON" or flowing).
3. Gun distance from work 3 to 4 inches.
4. Move gun over surface uniformly to give coverage over complete surface.
5. Continue buildup with selected material using parameters specified in material bulletin.
Finishing:
Deposit thicknesses of up to 0.080 must be finished by turning.
Hazards:
practices, see AWS Publications AWS C2.1-73, "Recommended Safe Practices For Thermal Spraying" and AWS

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-30T
Issue: K10320
Supercedes: J10208
Praxair and TAFA Arc Spray Medium Carbon

Steel Wire - 30T
Material Review:
Made exclusively for arc spraying, 30T is a manganese compensated, economical material used where great
thicknesses are not required (up to 0.080 inch) and hardness is not of paramount importance.
Praxair and TAFA's 30T steel is a medium shrink material, it requires grooves at edges where the coating is over
0.030" thick. Due to the material's porosity, the coatings give high wear resistance in lubricated service.
Arc Spray 30T Steel can be sprayed with any Praxair and TAFA Arc Spray gun.
Arc Spray 30T Steel wire meets Department of Defense Specification MIL-W-6712C, Table I, Carbon Steel,
0.25C.
Application Review:
This is one of the most economical materials for normal reclamation of worn or mismachined bearing and seating
surfaces for slow or high speed running, shafts, press fits, ball bearing housings, valve stems, pistons, etc.
Composition:
Carbon 0.15/0.23
Phosphorus Trace
Sulphur Trace
Manganese 1.0/1.5
Silicon 0.35 max.
Iron Balance

Melting Point 2192-2732F (1200-1500C) (approx.)
Hardness 97-100 Rb (250 Brinell)

336 Knoop100
2

2 2


rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
Normal ArcJet ArcJet Standard
8830/35 8830/35 9000 9000
c c c c
c c
Secondary --- 40 60 ---
Nozzle/Positioner (Cross=C; Short C ** Long C Long C
Slot=S)
a
Arc Load Volts 29-30 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300
popping.

--------------------------
a
b
c
Page 3
Use of Praxair and TAFA's 75 Wire as a Bond Coat:

In most applications Praxair and TAFA's 75B BondArc wire eliminates the need for surface roughening. The
Note again that the 75B coating does not self bond on many non-ferrous materials and normal surface
It must be a clean white metal surface free of grease, oil and handprints.
6. Continue buildup with selected material using 50 psig spray pressure on console (this 50 psig is for general
metallizing; for coarser coatings decrease 5 psig; for finer coatings increase 5 to 10 psig, depending on the
finish required).
Finishing:
Deposit thicknesses of up to 0.080 must be finished by turning, but can be machined or ground.
Hazards:

Telephone: 1-317-240-2650 Fax: 603-225-4342

Pagetrademarks
4 of their respective owners.

File: 1.9.1.2-35MXC
Issue: 011111
Supercedes: M10206
Praxair and TAFA Arc Spray High Carbon Steel

Micromatrix-Composite Wire - 35MXC
Material Review:
Made exclusively for arc spraying, its characteristics are its resistance to wear and the ability to spray extremely
rough, high profile, non-skid coatings, with significantly higher hardness properties. The bond strengths of arc
sprayed 35MXC is superior to that of comparable high profile coatings of low- and high-carbon steel. 35MXC can
be sprayed with any Praxair and TAFA Arc Spray gun.
causes problems such as excessive tip wear, spitting and feeding problems. We only recommend Praxair and
Application Review:
Anti-skid coatings have historically been applied by two commercial methods.
The first is a paint vehicle to hold abrasive particles. Such an approach limits the degree of roughness and
corrosion protection.
The second method, arc spraying, involves the application of a rough coat of arc sprayed aluminum or high
carbon 35MXC steel wire onto a metal substrate such as the deck of a ship, or a metal walkway.
For many years, manufacturers of walkway gratings have used low or high carbon steel wires to apply a non-skid
coating. The new 35MXC material gives the ability to spray at a high spray rate, and produce extremely well-
bonded high profile coatings. The 35MXC is a micromatrix-composite wire material, specially developed for this
application, with significant advantages in terms of higher bond strengths, higher deposit efficiencies, and
significantly higher hardnesses.
The coating can be galvanized, or top-coated with Praxair and TAFA 02Z Arc Sprayed zinc for corrosion
resistance.
MXC is a registered trademark of Praxair and TAFA Incorporated, Concord, NH

Procedures:
System I - in this case, a dense coating of 35MXC is applied to the steel for significantly higher bonding, followed
by a rough anti-skid topcoat. Typically, 2 to 5 mils of 35MXC are applied, using the Praxair and TAFA Model
8830or 8835 gun to obtain a dense, well-bonded coating. A second coat of 20 to 40 mils of non-skid material is
then applied with special gun parameters.
System II - in this system, a one-step rough coating is directly applied without the bond layer; this system is used
on certain substrates where adequate bond is achieved.
Application rates are calculated as follows:

2 2
Anti-Skid Coat 20 mils x 0.5 oz/ft /mil x 1/16 oz/lb = 0.5 lbs/ft
The cost of applying the coatings is as follows:
Metal Cost $4.50/lb

2 2
Anti-Skid Coating 0.5 lbs/ft x $4.50/lb = $2.25/ft
Air & Electricity - 0.04
2
TOTAL = $2.29/ft
The above spray rates are wire consumption rates. In the case of anti-skid coatings, the spray rate at 350 amps
2
yields 35 lbs/hr; i.e., 10 lbs/hr x 100 amps. Assuming 100% on-time, this yields an application rate of 140 ft /hr at
the rate of 350 amps with a 20 mil thick coating. This coating can be applied manually in small areas, but are
best applied on large areas, using automated equipment.
Surface Preparation:
Grit blast surface with 24-mesh aluminum oxide to a white, clean finish, using the pressure blaster. SSPC-5 or
better is recommended.
Application Parameters Anti-Skid Coat Dense Wear Coat

Amperage 200-350 200-350
Volts 27-30 27-30
Nozzle Cap Blue Blue
Nozzle/Positioner (C=Cross; S=Slot) Short C, S Short C, S
Standoff 4 inches 5 inches
Air Pressure 15 psi 50 psi
Gun 8830 or 8835 (anti-skid module) 8830 or 8835
Wire Size 1/16" 1/16"
Thickness/pass 20 mils (on 1/4" substrate) for anti-skid
coatings 2-5 mils for dense wear coatings
NOTE: Air pressure, amperage (spray rate), coating thickness and standoff will vary with substrate
thickness and roughness profile desired.
Page 2

Wire Size 1/16"
Deposit Efficiency* 90 Percent*
Melting Point 2500F
Bond Strengths* 8420 psi (58.1 MPa) Blasted Surface
Tensile Strength 38000 psi (262 MPa)
Coating Texture* Extremely Rough***
Hardness* (superficial) 15N 60-65
Coating Density* 6.78 gm/cc**
Spraying:
2 2
Coverage (wire consumption) 0.5 oz/ft /0.001" (0.6 kg/m /100 microns) - anti-skid
coatings
2 2
0.9 oz/ft /0.001" (1.10 kg/m /100 microns) - dense
wear coatings
Spray Pattern (approximate 8" standoff)*** Cross Nozzle/Positioner - 1 in (2.5 cm)
Using excessive voltage reduces quality of coatings. Voltage should be adjusted to give minimum noise and
smooth arc operation. Excessive voltage cause larger particles and poor spray pattern. Too low a voltage will
cause popping.
Be sure not to overheat the substrate even if this means stopping to allow cooling. Use air jet cooling, if
greater speed is required.

** Depends on atomizing air pressure, standoff, amperage.
diameter pattern and smoothest coating.
Page 3
Hazards:
practices, see AWS Publications AWS C2.1-73 "Recommended Safe Practices for Thermal Spraying", and AWS
when performed in accordance with safety measures. Become familiar with local safety regulations before

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-38T
Issue: K10320
Supercedes: J10208
Praxair and TAFA Arc Spray High Carbon

Steel Wire - 38T
Material Review:
Made exclusively for arc spraying, 38T is a manganese compensated, economical material used where hardness
is of paramount importance.
Praxair and TAFA's 38T steel is a low shrink material; it requires grooves at edges where the coating is over
0.030 inch thick. Due to the material's porosity, the coatings give high wear resistance in lubricated service.
Arc Spray 38T Steel wire meets Department of Defense Specification MIL-W-6712C, Table I, Carbon Steel,
0.80C.
Application Review:
surfaces for slow or high speed running, shafts, press fits, ball bearing housings, valve stems, pistons, crankshaft
bearings, seal rings, pump plungers, piston cylinder lines, match plates, etc.
Used where a low shrink steel is required. Can be used for casting defects and repair of castings such as heads
and engine blocks. Use it instead of 60T where color match with substrate is required.
Composition:
Carbon 0.80
Phosphorus 0.04
Sulhpur 0.03
Manganese 0.70
Silicon 0.10
Iron Balance

Coating Finish Excellent
Hardness Micro Rc 23

2

2 2


rough with low psi.
diameter pattern.
Page 2
Spraying Procedure
Coating Type
Normal ArcJet ArcJet 9000 Standard 9000
8830/35 8830/35
c c c c
c c
Secondary --- 40 60 ---
Nozzle/Positioner Short Cross ** Long Cross Long Cross
a
Arc Load Volts 29-30 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300
Thickness/Pass-mils 5 5 5 5
Texture-microinches aa 200-350 150-250 150-250 200-350
popping.

--------------------------
a
b
c
Page 3
Use of Praxair and TAFA's 75B Wire as a Bond Coat:

6. Continue buildup with selected material using 50 psig spray pressure on console (this 50 psig is for
general metallizing; for coarser coatings decrease 5 psig; for finer coatings increase 5 to 10 psig,
depending on the finish required).
Finishing:
Deposit thicknesses of up to 0.080 inch must be finished by turning, but can be machined or ground.
Hazards:
TSS-85, "Thermal Spraying, Practice Theory and Application." Thermal spraying is a completely safe process
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.

Telephone: 1-317-240-2650 Fax: 603-225-4342


Page 4
File: 1.9.1.2-39T
Issue: M10827
Original Issue
Praxair and TAFA Arc Spray High

Carbon Steel Wire - 39T
Material Review:
Made exclusively for arc spraying, 39T is an economical material used where hardness is of paramount
importance. The 28% improvement in micro hardness is developed because the carbon content is about
twenty points higher than 38T.
Praxair and TAFA's 39T steel is a low shrink material; it requires grooves at edges where the coating is over
0.030 inch thick. The coating has porosity about the same as 38T. The hardness with a small amount of porosity
gives high wear resistance in lubricated service.
Application Review:
surfaces for slow or high speed running, shafts, press fits, ball bearing housings, valve stems, pistons, crankshaft
bearings, seal rings, pump plungers, piston cylinder lines, match plates, etc. 39T produces harder coatings than
38T with the same parameters due to the higher starting carbon content.
Used where a low shrink steel is required. Can be used for casting defects and repair of castings such as heads
and engine blocks. Use it instead of 60T where color match with substrate is required.
Composition:
Carbon 1.0 Nominal
Chromium 1.5 Nominal
Silicon .25 Nominal
Manganese .35 Nominal
Iron Balance

Bond Strength 6204 psi (43 MPa) blasted surface
Coating Finish Excellent
Superficial Hardness HRC 23 Standard (converted from H15N)

HRC 28 ArcJet (converted from H15N)
Micro Hardness HRC 47 Standard (converted from DPH300)
HRC 43 ArcJet (converted from DPH300)
2
Spraying:
2 2


rough with low psi.
diameter pattern.
Page 2
Coating Type
Normal Arc Jet Arc Jet 9000
8830/8835 8830/8835 9000
c c
Secondary --- 40 60 ---
a
Arc Load Volts 29-30 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300
Coating Thickness/Pass-mils 3-5 3-5 3-5
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 coating application speed is required. Note that on some applications where preheating is
tolerable, preheating work to 300F can improve bond and deposit efficiency.

** P/N 620074 ArcJet Modified Short Cross (8830 & 9000)
--------------------------
a
recommended voltage setting for a given wire if the extension is increased to a 50 foot length.
b
c
Page 3
Use of PRAXAIR and TAFA's 75B Wire as a Bond Coat:

In most applications PRAXAIR and TAFA's 75B BondArc wire eliminates the need for surface roughening. The
Finishing:
Deposit thicknesses of up to 0.080 inch must be finished by turning, but can be machined or ground.
Hazards:
TSS-85, "Thermal Spraying, Practice Theory and Application." Thermal spraying is a completely safe process
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.
75B and BondArc are registered trademarks of Praxair and TAFA Incorporated, Concord, N.H.
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.

Telephone: 1-317-240-2650 Fax: 603-225-4342

Pagetrademarks
4 of their respective owners.

File: 1.9.1.2-45CT
Issue: 010928
Supercedes: 010729
Praxair and TAFA TAFALOY 45CT Wire

Material Review:
45CT wire is a Nickel/Chrome/Titanium wire developed specifically for boiler applications. This second
generation material replaces 06BXP and produces coatings which are extremely resistant to corrosive vanadium
and sulfur gases in boiler atmospheres.
The material is prealloyed with titanium to produce superior bond strengths and is suitable for a one-coat system.
The unusual self-bonding ability of the alloy is attributed to the exceptionally high temperatures of the metal
particles which on impact with the base metal diffuse to form a partial metallurgical bond.
Metallurgical tests show negligible chrome loss during spraying. Coating porosities less than one percent are
produced with negligible through porosity, thus maximizing the corrosion barrier characteristics of the material.
Application Review:
This material has proven very effective in providing long term protection to boiler tubes against high temperature
sulfidation. The wrought material is highly resistant to sulfur/vanadium atmospheres up to 1800F. Wrought
material of this type has shown a 2 mil per year corrosion rate over a nine year period when used in the super
heater section of boilers. Coatings of 45CT wire applied to boiler tubes have shown virtually no loss of thickness
or spalling after 24 months of service (as of this writing).
Tests have shown the high chromium content, in conjunction with nickel, greatly improves the heat corrosion
resistance of the alloy. Specifically, a chromium content of 40% or more is sufficient to form enough chromium
oxide to prevent the breakdown of nickel into nickel sulfide which is not a protective layer. Sixty-four day
accelerated corrosion tests of this material are highlighted in Figure 1. These tests were all run in the same test
boat at the same time to assure identical environments. Specifically the specimens were surrounded with a
synthetic smelt consisting of sodium chloride, sodium sulfate and sodium carbonate
The tests generally followed those of Dr. A. Plumbley and R.G. Tallent of Combustion Engineering, Inc. Figure
1 is self-explanatory; both the plasma sprayed and multicoat materials deteriorated significantly in 35 to 40 days.
Coatings made with 45CT wire on the other hand showed virtually no weight loss over the entire 64-day test. This
superior corrosion resistance has been proven out in extensive on-line boiler tests.
TAFALOY is a registered trademark of PRAXAIR and TAFA Incorporated, Concord, N.H.

45CT wire has been metallurgically engineered to match closely the thermal expansion characteristics of boiler
tube material. A178 low carbon steel is a typical boiler tube material which is commonly used.
Composition of A178
Carbon 0.06 - .18
Manganese 0.27 - .63
Phosphorus 0.050 max
Sulfur 0.060 max
Iron Balance
Field experience in actual boilers (after over a year and a half as of this writing) has shown that this close match
of coating and substrate is critical to preventing spalling of the coating. Figure 2 shows the final expansion rate of
45CT wire, A178 and a plasma applied iron base material.
The high deposit efficiencies achieved with this material coupled with significantly higher spray rates without
coating deterioration contribute to application cost reduction.
Coatings of 45CT wire can be deposited up to feathered edges of the same material at a later date to extend the
coating or repair or patch coatings mechanically damaged in service.
Composition:
Titanium 0.3-1 percent
Chromium 42-46 percent
Other 0.5-1.85 percent
Nickel Balance
Coating Physical Properties:

Melting Point 2700F(1482C)(approx.)
Bond Strength 6,900 psi (48 MPa)
Tensile Strength 24,000 psi (165.5 Mpa)
Coating Texture 300-350 microinches aa
Microhardness 313 HKN100 (RC 32)
Coating Porosity Less than 1 percent

2
Spraying:
2 2
Coverage (wire consumption) 0.8 oz/ft /0.001" (0.98 kg/m /100 micron)
* Up to 90 percent on large surface - Consult Factory
Page 2
Spraying Procedure:
8830 8850 9000 (No ArcJet Air)
Atomizing Gas Pressure 50 50 50
Nozzle Cap Blue Blue Blue
Nozzle/Positioner (Cross = C, Slot = S) Short C, S Short C, S Short C, S
Arc Load Volts 27-29 27-29 27-29
Amps 200-350 200-350 200-350

Coatings of 45CT wire can be deposited up to feathered edges of the same material at a later date to extend the
coating or repair or patch coatings mechanically damaged in service.
Standoff Inches (cm) 6-7 (17) 5-6 (15) 5-6 (15)
Coating Thickness/pass - mils 5 (125) 5 (125) 5 (125)

(microns)
Coating Texture - microinches aa Medium 300-350 Medium 300-350 Medium 300-350
Finishing:
Coatings of 45CT wire are finished (if required) by machining or grinding. Machining gives a fair finish and
grinding gives a good finish.
Hazards:
Chrome is under investigation in the welding industry as a toxic substance. Full respiratory protection should be
used when spraying this material.
Publication AWS C2.1-73, "Recommended Safe Practices For Thermal Spraying" on general spray practices and
supplied before you have thoroughly read the PRAXAIR and TAFA Instruction Manual.
Page 3

Telephone: 603-224-9585
Telephone: 1-317-240-2650
Fax: 603-225-4342
Fax: 1-317-240-2596

Page 4

File: 1.9.1.2-55T
Issue: K10320
Supercedes: J10208
Praxair and TAFA Arc Spray 18/5

Stainless Steel Wire - 55T
Material Review:
Made exclusively for arc spraying. Characteristics of the coating are its excellent resistance to corrosion, low
shrink, and better machinability. Uses are similar to those of 18/8 Stainless.
Arc Spray 55T Stainless wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Arc Spray 55T Stainless wire meets Department of Defense Specification MIL-W-6712C, Table I, Stainless, 18/5.
Application Review:
Primary usefulness is for coating inside diameters where shrink has previously been a major problem, and where
heavy coatings are required. Coating applications have been rebuilt hydraulic rams, food industry rollers, and a
variety of machine elements.
Composition:
Carbon 0.06
Phosphorus Trace
Sulphur Trace
Manganese 8
Nickel 5
Chromium 18
Silicon 0.08
Iron Balance

Bond Strength 4156 psi blasted surface (28.7 MPa)
Coating Texture Variable**
Hardness 92-94 Rb 360 Knoop100

2
Shrink 0.008 in/in (cm/cm) (approximate)

2 2
Spray Pattern***(approximate 8" standoff) Cross Nozzle/Positioner - 1" (2.5 cm)


rough with low psi.
*** Higher air pressures, smaller wire (1/16"), and lower amperage with red nozzle cap gives smallest
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
Normal Arc Jet Arc Jet 9000 9000
8830/8835 8830/8835
c c c c
c c
Secondary --- 40 60 ---
a
Arc Load Volts 29-30 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300
popping.

--------------------------
a
b
c
Use of Praxair and TAFA's 75B ire as a Bond Coat:
Page 3
Finishing:
Arc spray 55T may be machined easily or ground to achieve a desired finish.
Hazards:
All chromium alloys produce hazardous fumes. While spraying, all personnel should be made aware of the need
for complete respiratory protection. Observe normal spraying practices, respiratory protection and proper air flow
patterns advised. For general spray practices, see AWS Publications AWS C2.1-73, "Recommended Safe
Practices for Thermal Spraying," and AWS TSS-85, "Thermal Spraying, Practice, Theory and Application."
Thermal spraying is a completely safe process when performed in accordance with proper safety measures.
Become familiar with local safety regulations before starting spray operations. DO NOT operate your spraying
equipment or use the spray material supplied before you have thoroughly read the Praxair and TAFA Instruction
Manual.

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-58T
Issue: 011012
Supercedes: N10624
Praxair and TAFA Arc Spray Copper-Nickel

Indium Wire - 58T
Material Review:
Made exclusively for arc spraying as an essentially Copper-Nickel Indium wire. Praxair and TAFAs 58T produces
low porosity coatings and when machined, yields a dense finish. Praxair and TAFAs 58T with the addition of
indium probably increases the lubricity and antigalling characteristics of the coating. This coating is designed to
meet the requirements of aircraft specifications
Arc Spray 58T Copper-Nickel Indium wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Application Review:
Used primarily as a root coating on aircraft turbine blades to resist fretting wear and for machine element work
where conditions involve higher temperatures and necessitate corrosion protection. Some examples beside
blade roots include resurfaced pump plungers, impellers, rams, pump sleeves, shafts, seal rings, casings, valve
plugs, and wedges. The applications include seal joints and other parts that see low temperature fretting with no
intended motion. Also used to attach graphite to current lugs an some nuclear industry anodes. Coating
thicknesses vary between .001" and .040", dependent on application.
Composition:
Nickel 36.5%
Indium 5.0%
Copper Balance

Bond Strength Good
Coating Texture (as sprayed) Variable** (see next page)
Hardness 48 Rb

2 2
Coating Weight 0.039 lbs/ft /mil (.74 Kg/m /0.1 mm)
Bond Strength 4400 psi (2750)
Spraying:
2 2


rough with low psi.
*** Depends on atomizing air pressure and standoff.
diameter pattern.
Page 2
Spraying Procedure
Coating Type
8830/8835 8830/8835 9000
c c c c
c c
Secondary --- 40 60 ---
Slot=S)
a
Arc Load Volts 28-30 28-30 28-32 28-30
b
Amps 75-150 75-150 75-150 75-150
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
NOTE: Standard air caps and positioners can be used in 8830 systems.

** P/N 620074 Arc Jet Modified Short Cross (8830)
--------------------------
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 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
c
Page 3
Finishing:
Copper-Nickel alloys are usually finished by machining or grinding. Conventional tool shapes are used and light
cuts and high work speeds give best results.
Hazards:

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-60T
Issue: 010624
Supercedes: K10320
Praxair and TAFA Arc Spray 13% Chrome

Steel Wire - 60T
Material Review:
Made exclusively for arc spraying. Characteristics of the coating are its excellent wearing quality and fair
resistance to corrosion. It is excellent all-purpose steel for basic machine element work.
Arc Spray 60T Chrome Steel wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Arc Spray 60T Chrome Steel wire meets Department of Defense Specification MIL-W-6712C, Table I, Stainless
Steel, Chrome and Rolls Royce's MSRR 9507/103 Specification.
TAFA Certified wires.
Application Review:
This is by far the most widely used reclamation spray wire because of its wear resistance and low shrink.
Recommended when a hard coating requiring some corrosion resistance is desired. The high chrome content
provides fair high temperature oxidation resistance and provides a fair amount of corrosion protection.
In addition, the chrome steel serves as an electrical resistance coating. Successful shop applications have been
resurfaced journal sections, cylinder liners, pistons, crankshaft bearings, hydraulic rams, and numerous other
machine elements.
Some electrical power stations use only this steel for repair work.
Composition:
Carbon 0.3
Phosphorus Trace
Sulphur Trace
Manganese 1.0
Nickel 1.0
Chromium 12/14
Silicon 0.08
Iron Balance

Coating Texture (as sprayed) Variable** (see next page)
Finish Texture (ground) 6-15 Microinches aa **
Hardness R15n 80-82 (Rc 40-43) Converted
Coating Density 6.74 gm/cc**

2

7
Coefficient of Thermal Expansion 6.6 x 10- in/in F (1000F)

2 2


rough with low psi.
*** For higher hardness increase air pressure to 60 psi or higher do this only in final passes where wear
will occur.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/8835 8830/8835 9000
c c c c
c c
Secondary --- 40 60 ---
a
Arc Load Volts 29-30 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300
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 300F can improve bond and deposit efficiency.
* P/N 450729 8830 Arc Jet Air cap

--------------------------
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 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
c
Page 3
Use of Praxair and TAFAs 75B Wire as a Bond Coat:

In most applications Praxair and TAFAs 75B BondArc wire eliminates the need for surface roughening. The
2. Set spray pressure air at 50-60 psig (do this while air is ON or flowing).
3. Run at 150 amps at 30 load volts

5.
finish required).
Finishing:
The coating is usually best finished by grinding. The user may experiment with carbide tools, which gives only a
medium finish. The preferred method of i.d. work is to carbide turn leaving a 0.020 deposit for honing to finish
size. If deposit is initially ground, leave 0.005 inches for honing. Grind with silicon or alumina wheel with particle
size of 30-50.
Shop Experience:
Spray Parameters
Amps: 150
Volts: 29
Atomizing Pressure: 60 psi
Nozzle Cap: Blue
Nozzle/Positioner: Short Cross
Spraying was done by hand.
The parts were returned to the machine shop for finishing.
Grinding Parameters:
Machine: Brown & Sharpe 6" x 18" surface grinder
RPM: 3600
Wheel Size & Type: Norton 32A46-H8VBE 7" x 1/2" x 1-1/4"
Coolant: IRMCO (International Refining & Mfg. Co.) #120 Spray Mist
Feed: Manual
Depth of Cut: 0.0015" roughening
0.0005" finish
Results:
A 32 microinch aa finish was obtained from both wheel face and side. Spray material did not chip from base metal or
show cracks from heat in grinding.
Page 4
Hazards:
for proper respirator protection. Observe normal spraying practices, and proper air flow patterns. For general
spray practices, see AWS Publication AWS C2.1-73, "Recommended Safe Practices for Thermal Spraying" and

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 5
File: 1.9.1.2-70T
Issue: K10309
Supercedes: J11018
Praxair and TAFA Arc Spray Nickel-Copper

Alloy Wire - 70T
Material Review:
Made exclusively for arc spraying. This alloy is used where it is necessary to provide load bearing, corrosion-
resistant surfaces, particularly in seawater and caustic environments. 70T produces dense coatings which are
easily machinable.
Arc Spray 70T can be sprayed with any Praxair and TAFA arc spray gun.
Arc Spray 70T wire meets Department of Defense Specification MIL-W-6712B, Table II, Nickel-Copper.
Application Review:
Due to its corrosion-resistance characteristics, 70T provides protection for machine elements where the hardness
is sufficient for steam valve components, shafts (propeller, tail, crank, etc.), pump plungers, seal rings, hydraulic
pumps, etc. Especially ideal where immersion in sea water would present difficulties for the softer metals. Highly
suitable, as well, for bores and low shrink applications.
Composition:
Nickel 67
Carbon 0.25 Max.
Sulphur Trace
Iron 2 Max.
Manganese 1.5 Max.
Silicon 0.25 Max.
Aluminum 0.10 Max.
Copper 27

Tensile Bond Strength 4310 psi (29.7 MPa)
Hardness 80-84 Rb

2
Shrink 0.002 (approx.)

2 2


rough with low psi.
*** For higher hardness increase air pressure to 60 psi or higher do this only in final passes where wear
will occur.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/8835 8830/8835 9000
c c c c
c c
Secondary --- 40 60 ---
a
Arc Load Volts 30-32 30-32 31-33 31-33
b
Amps 100-200 100-200 100-200 100-200

--------------------------
a
foot length.
b
c
Page 3
Use of Praxair and TAFAs 75B Wire as a Bond Coat:

In most applications Praxair and TAFAs 75B BondArc wire eliminates the need for surface roughening. The
2. Set spray pressure air at 50-60 psig (do this while air is ON or flowing).
3. Run at 150 amps at 30 load volts
finish required).
Finishing:
The coating should be finished by grinding or machined at low speed with carbide tools.
Hazards:

Telephone: 603-224-9585
Telephone: 1-317-240-2650
Fax: 603-225-4342
Fax: 1-317-240-2596
Technology, Inc. in the United States and/or other countries. TAFA Incorporated is a Praxair Surface Technologies company.
Page 4
File: 1.9.1.2-71T
Issue: M11029
Supercedes: K10328
Praxair and TAFA TAFALOY Nickel-

Chrome-Moly Wire - 71T
Material Review:
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.
Application Review:
TAFALOY Nickel-Chrome-Moly wire has proven very effective as a coating material in paper mill digesters.
Traditionally, weld overlay of high nickel alloys has been used to prevent caustic stress corrosion cracking of the
carbon steel substrate in continuous digestors. Weld overlay has proven effective, but extremely costly.
Arc sprayed 71T is an economical alternative to overlaying. Coupled with a sealer, a 0.070-inch thick coating will
provide continuous protection with virtually no loss of coating thickness. The sealer can be effective to 1200F
and is critical to preventing the caustic medium from penetrating through the coating to the substrate.
TAFALOY 71T, coupled with an appropriate sealer, should also be considered for service in many acidic
environments.
TAFALOY is a registered trademark of TAFA Incorporated, Concord, NH

Composition:
Nickel 62.5
Chromium 22.0
Moly 10.0
Iron 2.0
Other 3.5

Melting Point 2400F
Bond Strength 7000 psi (48 MPa)
Tensile Strength 24,000 psi
Macrohardness 92 Rb

2

Spray Rate 11 lbs./hr/100 amps (5 kg/hr/100 amps) 3 lbs/hr/100
2 2
Coverage (wire consumption) 0.8 oz/ft /0.001" (0.98 kg/m /100 micron)


rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
These are starting parameters only. Optimum will vary depending on application, utilities, environment, spray rate
and equipment.
Coating Type
Standard 8830/8835 Standard 8850 Standard 9000
c c c
Secondary --- --- ---
Nozzle Cap Blue Green Green
Nozzle/Positioner (Cross=C; Short C Long C Long C
Slot=S)
a
Arc Load Volts 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300
popping.
--------------------------
a
b
c
Page 3
Hazards:

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-73MXC
Issue: 011111
Supercedes: K10328
Praxair and TAFA Arc Spray Nickel Chrome

Aluminum Micromatrix-Composite Wire-73MXC
Material Review:
73MXC is a nickel chrome aluminum alloy (NiCrAl) designed to be self-bonding, have higher oxidation resistance
and better machinability than comparable products. Specifically designed for selective removal in acid baths.
73MXC is a unique cored wire product for use in arc spray systems. It is available exclusively from Praxair and
TAFA. Measured bond strengths exceed 7500 psi at 0.020" thickness. Additionally, the bond strength of 73MXC
depends on thickness. At 0.060" the coating still retains in excess of 4500 psi tensile bond strength. A graph of
bond strength versus thickness appears in Figure 1. 73MXC can be sprayed with any Praxair and TAFA arc
spray equipment. In many instances, use of the Arc Jet is preferred (See Bulletin 1.1.8.4).
Application Review:
Arc spray coatings of 0.004" to 0.006" can be readily

applied in one pass. Thicker coatings up to 0.100" have
been applied by continuous spraying. 73MXC can be
machined to a 32 microinches (AA) finish using Tungsten
Carbide tools or ground to a smooth finish with aluminum
oxide or silicon carbide wheels. The surface should be
prepared by grit blasting (60 mesh aluminum oxide at 60
psig blast pressure). In all cases the surface to be sprayed
must be clean and exhibit freshly exposed metal.
MXC and Arc Jet are a registered trademarks of TAFA Incorporated, Concord, NH
73MXC is specifically formulated to meet the following specifications: PWA 36947 for PWA 271-47 Rev D, Rolls
Royce MSRR9507/14, and GE Manual operation number 70-49-39 as an alternate to 70-49-21. The chemistry of
this material conforms to G.E. Specification B50TF 119-S10 Rev.
Special Properties:
73MXC is specifically designed to allow for selective removal in an acid bath environment. Specifically Ni-5 Al
such as Praxair and TAFA's 75B can be effectively removed in a 50% concentration of nitric acid at 160F,
however, the 73MXC coating will not be removed under these conditions, thereby allowing for selective coating
removal during aircraft engine repair. 73MXC is unaffected by 50% nitric acid at room temperature. If complete
removal is required of both 73MXC and nickel aluminum, it is possible to do so with specific blends of hot nitric,
hydrochloric and phosphoric acids. These formulations are generally held proprietary by the aircraft engine
manufacturers. Contact your specific manufacturer for details.
Coating
Acid 73MXC Metco 443 Ni-5 Al
50% nitric
balance water No effect No effect etched
room temperature
50% nitric
balance water No effect No effect Etched
160F
Acid Blend A
balance water No effect No effect Etched
160F
Acid Blend B
balance water etched etched Etched
160F
Composition:
Nickel 70% minimum
Chromium 18% nominal
Aluminum 6% nominal
All Other Less than 6%
Page 2
A quick comparison between 73MXC and Metco 443:

73MXC M-443
Bond strength (psi)
a. at 0.015-0.020" 7500 4000*
b. 0.060" 4500 N/A
Hardness
a. RB 95 85-90
b. R15N 65
c. DPH300 240
d. KHN 220
Surface roughness (AA)**
a. as sprayed 300-700 300-700
b. as machined 30-40 30-40
Acid bath
a. 50% HN03 @ RT No effect No effect
b. 50% HN03 @ 160F No effect No effect
c. Acid Blend A @ 160F No effect No effect
d. Acid Blend B @ 160F etched etched
Other properties
a. spray rate (lbs/hr/100 amps) 8.5 6-8
b. coverage (oz/sqft/0.001") 0.7 0.64
c. deposit efficiency 80% 80%
* thickness = 0.015"
** depends on air pressure

Wire Size 1/16 in
Deposit Efficiency 80 percent
Melting Point 1250F (Aluminum Component)
a
Bond Strength Tensile 7500 psi blasted surface
b
Coating Texture (as sprayed) 550 microinch (AA) attainable
Hardness 65 R15N (95 RB converted)
Microhardness 240 DPH
c
Coating Density 6.2 gm/cc
2
Abrasion Resistance Good
Impact, Sharp Edge and Bend Resistance Good
-6
Coefficient of Thermal Expansion 7 x 10 in/inF
Heat Resistance Good
Corrosion Resistance Excellent
Spraying
Spray Rate 8.5 lbs/hr/100 amps (4.5 kg/hr/100 amps)
2 2
Spray Pattern (approximate 4 inch standoff) Cross Nozzle Positioner - 1 in (2.5 cm)
Length of Wire per lb 113 ft (1/16 in)
a
Values are for steel substrates according to ASTM C633-69
b
4 inch standoff, 50 psi - 8830, depends on nozzle cap, air pressure - fine with high psi, average with
c
Density depends on air pressure.
Page 3
Spraying Procedure:
Coating Type
8830/8835 8830/8835 9000
c c c c
c c
Secondary --- 40 60 ---
a
Arc Load Volts 30-32 30-32 31-33 31-33
b
Amps 100-200 100-200 100-200 100-200

** P/N 620074 Arc Jet Modified Short Cross (8830)
--------------------------
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 extension; i.e. add 3.4 volts to the
b
c
Page 4
Finishing:
An exceptionally good finish can be achieved by turning:
Surface Speed 110 fpm (0.08 m/s)

Traverse Speed 0.002-0.003 inches per rev.
Depth of Cut 0.015-0.025 in (250 micron) for first few cuts then 0.001-0.005 in (125 micron) to finish
Coated tungsten carbide and ceramic tools can be used to obtain a finish of 32 AA. Grinding can also be used to
obtain a good smooth finish. Dress frequently and do not permit coating to overheat. Cutting oil is not required.
High nickel alloys are difficult to finish. If a grinding wheel is used, it may tend to load up which in turn tends to
smear the coating or increase pull-out. If a cutting tool is used, even a ceramic or diamond tool, pull out may be
a problem on the very hardest coatings. However, it is fairly easy to generate a 20-microinch finish using the
correct grinding wheel and grinding technique. A 15-microinch finish can be obtained with care. Secondary
finishing is required below 10 microinches.
A typical grinding wheel specification obtained from Norton and others could be:
Silicon carbide
37 C
I hardness
8 porosity
Vitrified open wheel
Typical Grinding Setup:
Wheel rpm: Med/High

Shaft rpm: Low
SFPM: High with the work running opposite the wheel
Amount removed per pass 0.0005
Use very light pressure and clean wheel.
Super finishing with either silicon carbide or diamond cloth using a mineral base (non-sulfur) 5 to 10 weight
hydraulic oil or kerosene can produce finishes below 10 microinches AA. Typically, it is a good idea to start with a
240 grit paper, then progress to 320, 400 and perhaps to 600, 1200, even 4000. If diamond cloth is selected, one
should use a 9 to 15 micron particle size (obtained from 3M or others).
The objective is to use the 240 cloth to completely remove the grinding marks from the 37C wheel. Then, use the
320 cloth to remove the marks from the 240 cloth. Then use the 400 --- and so on. If one switches to the finer
cloths too soon, a high polish will result on the "high spots", but many of the original deep grinding marks will
remain. Patience is the secret to the art.
Speeds & Feeds Dry Grinding Wet Grinding

Wheel Speed SFPM 6000 6000
Work Speed SFPM 60 70 rough
Wheel Traverse IPM 7 rough 12
2.5 finish
In Feed (inches) 0.001 rough 0.001
0.0005 finish 0.0005
Coolant -- Water Sol, 1-50
Page 5
Hazards:
Observe normal spraying practices, respiratory protection and proper airflow patterns advised. For general spray
practices, see AWS Publications AWS C2.1-73, "Recommended Safe Practices for Thermal Spraying and AWS

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 6
File: 1.9.1.2-74MXC
Issue: 011111
Supercedes: K10328
Praxair and TAFA Arc Spray Molybdenum Nickel

Aluminum Micromatrix-Composite Wire - 74MXC
Material Review:
74MXC is a molybdenum nickel aluminum alloy (MoNiAl) designed to be self-bonding, have a medium hardness
for bearing wear applications. They have good particle erosion resistance and toughness, performing well in
adverse environments without the "cracking" experienced when harder less tough coatings are used.
74MXC is a unique cored wire product for use in arc spray systems. It is available exclusively TAFA. Measured
bond strengths exceed 8000 psi at 0.010" thickness. Additionally, the bond strength of 74MXC depends on
thickness. At 0.060" the coating still retains in excess of 4500 psi tensile bond strength and at 0.100" thickness it
is still above 2500 psi. A graph of bond strength versus thickness appears in Figure 1. 74MXC can be sprayed
with any TAFA arc spray equipment. In many instances, use of the Arc Jet is preferred (See Bulletin 1.1.8.4).
This is a low shrink material especially recommended for reclamation of mismachined or worn parts.
CAUTION: Praxair and TAFA wires have been optimized for arc spraying. Use of alternate wires usually cause
problems such as excessive tip wear, spitting and feeding problems. We only recommend Praxair and TAFA
certified wires.
Application Review:
Arc spray coatings of 0.004" to 0.006" can be readily

applied in one pass. Thicker coatings up to 0.100" have
been applied by continuous spraying. 74MXC can be
machined to a 32 microinches (AA) finish or better using
Polycrystalline diamond tools or ground to a smooth finish
with aluminum oxide or silicon carbide wheels. Generally
the surface should be prepared by grit blasting (60 mesh
aluminum oxide at 60 psig blast pressure and 6" nozzle to
work distance). In all cases the surface to be sprayed
must be clean and exhibit freshly exposed metal.
74MXC is specifically formulated to meet the

following specifications: Air research FP5045, Rolls
Royce MSRR9507/35, and GE B50TF166, and
Garrett FP5045
Nickel Balance
Aluminum 5.5%
Molybdenum 5%
A quick comparison between 74 MXC and Metco 447

74MXC M-447
Bond Strength (psi)

a. at 0.015-0.020" 7800 5000*
b. 0.060" 4650 N/A
Hardness
a. RB 78 75-80
b. R15N 56
c. DPH 200 200
a. as sprayed 300-700 300-700
Other properties
a. spray rate (lbs/hr 200 amp) 17 6-8
b. coverage (oz/sq ft/0.001") 0.7 0.64
Wire Size 1/16 in
Deposit Efficiency 75 percent

a
b
Coating Texture (as sprayed) 300-700 microinch (AA) attainable
Hardness 86 R15T (Rb 78 converted)
Microhardness 200 DPH300

c
2
Abrasion Resistace Good

-6
Coefficient of Thermal Expansion 7 x 10 in/in
Wear resistance Good

a+
Values are for steel substrates according to ASTM C633-69.
b
c
Page 2
Spraying:
Coverage (wire consumption) 0.8 oz/ft 2 /0.001 in (0.98 kg/m2 /100 microns)
Spray Pattern (approximate 4 inch standoff) Cross Nozzle Positioner - 1 in (2.5 cm)
Length of Wire per lb 113 ft (1/16 in)
Spraying Procedure:
Coating Type
8830/8835 8830/8835 9000
c c
Secondary --- 40 30 ---
a
Arc Load Volts 30-32 30-32 31-33 31-33
b
Amps 100-200 100-200 100-200 100-200
and smooth arc operation. Excessive voltage causes larger particles and poor spray pattern. Too low
a voltage will cause popping.

--------------------------
a
b
c
Page 3
Finishing:
Coatings are capable of better spray finishes than 60T or 13T. Coating has dual capability - of acting as a bond
coat as well as a top coat.
Surface Speed of part 100-300 fpm (0.024 m/sec)
Traverse Speed:
rough cut 0.002-0.003 inches per rev
finish cut 0.0005-0.002 inches per rev
Depth of Cut
rough cut 0.010-0.020 in (250 micron)
finish cut 0.001-0.003 in (125 micron)
Best possible finishes can be obtained with a Polycrystalline Diamond insert with a negative rake.
a problem on the very hardest coatings. However, it is fairly easy to generate a 20 microinch finish using the
correct grinding wheel and grinding technique. A 15 microinch finish can be obtained with care. Secondary
finishing is required below 10 microinch.
Silicon carbide
37 C
I hardness
8 porosity
Typical Grinding Setup
Wheel rpm: Med/High

Shaft rpm: Low
SFPM: High with the work
running opposite the wheel
Page 4
320 cloth to remove the marks from the 240 cloth. Then use the 400 -- and so on. If one switches to the finer
remain.

2.5 finish
0.0005 0.0005
Hazards:
you have thoroughly read the TAFA Instruction Manual.
workpiece preparation and operator technique. TAFA warrants only that the wires are free of defects in
material and workmanship. No other warranty is expressed or implied.

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 5
File: 1.9.1.2-75B
Issue: L11111
Supercedes: K10328
Praxair and TAFA Arc Spray BondArc Wire75B

Material Review:
BondArc 75B wire, a unique nickel-aluminum alloy for use in arc spray systems, is available from Praxair and
TAFA on an exclusive license under U.S. Patent No. 4,027,367 and corresponding foreign patents. Tradenamed
BondArc, the pre-alloyed wire produces superior bond coats that are dense and resistant to high temperature
oxidation, thermal shock and abrasion. The material is equally suitable as a one-coat system; for example, a
finish of 5 microinch is attainable. BondArc wire is manufactured exclusively for wire arc spraying. The unusual
self-bonding ability of the alloy is attributed to the exceptionally high temperatures the nickel-aluminum reaches
and which on impact with the base material, diffuses to form a metallurgical bond. Measured bond strengths have
been determined to be 55 percent higher than those formed by exothermic reactions of nickel and aluminum
mixtures -- the previous materials available to demonstrate such self-bonding characteristics. One of the major
problems in achieving high quality, well-bonded coatings in any thermal spray process is the costly, extensive
preparation of the substrate. BondArc alloy eliminates the problem. The coating, through extensive testing, has
also been found to be superior to exothermic materials in sharp edge and impact loading.
BondArc wire is self-bonding to a broad range of smooth metal surfaces including annealed or hardened carbon
steels, annealed or hardened alloy steels, stainless steels, aluminum, nickel, cast iron, titanium and tantalum. It is
not self-bonding to copper-based alloys or tungsten. BondArc wire does not exhibit the same self-bonding
characteristics when sprayed with a conventional combustion flame or when rendered into powders and applied
by plasma spray apparatus. BondArc 75B wire can be sprayed with any Praxair and TAFA arc spray gun.
BondArc 75B meets the following specifications PWA-36937 (PWA 271-37 Rev D), GE Manual operation number
70-49-38 as an alternate to 70-49-10, Avco M3951B, Rolls Royce OMAT #3/229, SNECMA DMR33-011, Garrett
FP5045 and BF Goodrich Service Letter 1623.
Application Review:
Arc spray coatings from 0.004 to 0.006 inch (0.01 to 0.015 mm) can be readily applied in one pass. Thicker
coatings up to 0.250 inch (6.3 mm) have been applied by continuous spraying. Thus, in some cases, BondArc
can be used as a one-coat system. BondArc coatings can be machined to a rough finish with tungsten carbide
tools or ground to smooth finish with aluminum oxide or silicon carbide wheels. BondArc wire can be sprayed
directly on a smooth, chemically clean surface without conventional blasting, turning or roughening, thereby,
eliminating the need for expensive preparation equipment and the associated labor and quality control. However,
where possible, the surface should be prepared by rough cutting (thread), rough grinding, grit blasting (24 mesh
steel shot or aluminum oxide at 80 psig pressure blast) or using a clean coarse emery cloth since this increases
bond strength by an additional 600 psi. In any case, note that the surface to be sprayed must be clean, freshly
exposed metal. Since BondArc coatings look like stainless steel, it is cosmetically acceptable to many end users
as a finish coat.
Typical properties of the Praxair and TAFA nickel-aluminum arc spray coating when sprayed on a clean but
unroughened (unprepared) steel surface include: bond strength - 9100 psi; with a typical coating hardness of 55-
80 Rb.
Figure 1
Figure 2
Figure 3
Page 2
Nickel 95 percent
Al 5 percent

a
Bond Strength Tensile 9,100 psi clean surface (62.8 MPa)
9,750 psi blasted surface (67.2 MPa)
b
Coating Texture (as sprayed) Variable (see next page)
Hardness 55-80 Rb
c
2
Magnetic Properties Non-magnetic, slight magnetic susceptibility

-6
Coefficient of Thermal Expansion 7x10 in/inF (1000F)
Electrical Resistivity 200 micro ohm cm (appropriate)

d
Spraying:

2 2
e
Spray Pattern (approximate 8 in standoff) Cross Nozzle/Positioner - 1 in (2.5 cm)
vertical height x 1 3/4 in (4.4 cm) width
a
Values are for steel substrates according to ASTM C633-69. For bond strengths on other substrate
materials, see Figures 1, 2 and 3 on Page 2 and also Bulletin 1.9.1.2-75B.1.
b
c
Density depends on air pressure - 80 percent "Bond Coat" setting, 90 percent subsequent buildup.
d
No evident nickel alloy/substrate scaling with 0.020 inch coating after:
Five days @ 1000F
Three days @ 1800F
15 minutes @ 2200F
e
Higher air pressures, smaller wire (1/16), and lower amperage with red nozzle cap gives smallest
diameter pattern.
Page 3
Spraying Procedure:
Coating Type
8830/8835 8830/8835 9000
c c c c
c c
Secondary --- 40 60 ---
a
Arc Load Volts 30 30 30 30
b
Amps 100-300 100-300 100-300 100-300

--------------------------
a
foot length.
b
c
Page 4
Finishing:
Surface Speed 1.27 m/s (250 fpm)

Traverse Speed 38 cuts/cm (96 cuts/in) (0.0105 in)
Depth of Cut 250 micron (0.010 in) for first few cuts then
125 micron (0.005 in) to finish
Tungsten carbide tools can be used to obtain a rough finish and grinding to obtain a good smooth finish. Use light
cuts for roughing and finishing. Dress frequently and do not permit coating to overheat.
finishing is required below 10 microinch. Grinding must be taken in stages, working down in finish with
successively finer finishing surfaces.
Silicon carbide
37 C
I hardness
8 porosity
Typical Grinding Setup
Wheel rpm: Med/High

Shaft rpm: Low
Secondary finishing with either silicon carbide or diamond cloth using a mineral base (non-sulfur) 5 to 10 weight
hydraulic oil or kerosene can produce finishes below 10 with effort and art. Typically, it is a good idea to start with
a 240 grit paper, then progress to 320, 400 and perhaps to 600, 1200, even 4000. If diamond cloth is selected,
one should use a 9 to 15 micron particle size (obtained from 3M or others).
320 cloth to remove the marks from the 240 cloth. Then use the 400 -- and so on. If one switches to the finer
A recent series of a 1/2" diameter shafts were finished at Praxair TAFA following these principles. The finish on
the Bond Arc-coated shafts was judged to be "approaching 8 microinches"; i.e., definitely better than 16, but
clearly not as good as 4.
Page 5

2.5 finish
0.0005 finish 0.0005
Hazards:

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 6
File: 1.9.1.2-76MXC
Issue: 011207
Supercedes: M10303
Praxair and TAFA Nickel Chrome Aluminum

Yttrium Micromatrix-Composite Wire-76MXC
Material Review:
Made exclusively for arc spraying. This material produces coatings which resist corrosive gases and oxidation
temperatures up to 1800F. A coating of this material can also be used to resist heat and prevent oxidation
scaling of conventional low alloy steels. These coatings have also been used as an oxygen barrier under sprayed
coatings of ceramic. The coating is machinable. This material can be sprayed with any Praxair and TAFA Arc
Spray gun.
Application Review:
Praxair and TAFA 76MXC is used to produce oxidation and heat resistant coatings and oxidation resistant bond
coatings for ceramics. When applied 0.010" thick minimum, it will retard or prevent heat oxidation of carbon
steels and low alloy steels to temperatures of 1800F. At 0.005", coatings used as a bond coat for ceramics have
been found to retard or prevent heat oxidation of the base material. Thicknesses of 0.002" to 0.003" are
adequate for bonding ceramic coatings to an oxidation-resistant base material. The material has also been used
as an excellent bond coat with bond strengths considerably higher than stainless steels.
It has been found through experiments that corrosion can occur under ceramic coatings directly applied to iron
alloys, stainless steels and alloys of aluminum and nickel. Both sale and other chloride atmospheres accelerate
this corrosion phenomenon. Currently inadequate information is available to determine whether this corrosion
phenomenon may apply to other corrosive atmospheres as well when ceramic coatings are applied directly to a
metal substrate which develops passive oxide films. It is felt that this corrosive condition comes about because of
the loss of protective oxide films during the grit blasting operation prior to ceramic coatings. The corrosion can be
identified in some cases by observing the ceramic coating which has failed and noticing the characteristic red
iron oxide or white aluminum oxide. In the case of salt environments, it appears that some electrochemical
reactions are accelerated. It has been found in laboratory investigations that the corrosion is significantly inhibited
when the Praxair and TAFA 76MXC wire coat is used. The procedure in this case is to apply 0.002" - 0.005" of
the barrier coat with coatings on the thinner end of the tolerance used where fine sprayed surface finishes are
required and the thicker end when a coarse ceramic powder is utilized. Other areas where this material could be
used would be exhaust valve stems, heat treat fixtures, and dimensional and building any manufacturing
equipment that has temperature and corrosion environments.
MXC is a registered trademark of TAFA Incorporated, Concord, NH

Composition:
Nickel 67%
Chromium 22%
Aluminum 10%
Yttrium 1%

Bond Strength 10,800 psi (75.6 Mpa)
Macro hardness 52-90 Rb*

-6
Coefficient of Thermal Expansion 12.9 x 10 in/in (cm/cm) F
Finish - machined: 40-66 AA

Ground: 10-30 AA
Spraying:
2 2
Spray Pattern****(approximate 3-5" standoff) ArcJet parameters with 60/50 psi air pressure and 3"
standoff produces the smallest spray pattern.
Length of wire per lb 121ft. (1/16")

*** Depends on atomizing air pressure and the use of an ArcJet.
Page 2
Spraying Procedure
Coating Type
8830/8835 8830/8835 9000
c c c c
c c __
Secondary --- 40 60
Nozzle Cap Blue ** Green Green
a
Arc Load Volts 30-32 30-32 31-33 31-33
b
Amps 100-200 100-200 100-200 100-200
Note: Standard air caps and positioners can be used in 8830 or 9000 systems.

--------------------------
a
increased by approximately 3.4 volts per 50 foot extension; i.e. add 3.4 volts to the recommended
b
c
Page 3
Finishing:
Praxair and TAFA 76MXC is usually finished by machining or grinding, with machining giving a fair finish and
grinding giving a good finish.
Hazards:
Copyright 2000 Praxair Technology, Inc. All rights reserved psti-info@praxair.com
www.praxair.com/thermalspray Telephone: 603-224-9585
Fax: 603-225-4342
Telephone: 1-317-240-2650
Fax: 1-317-240-2596 subject to change without notice
Praxair, the Flowing Airstream design and Making our planet more TAFA Incorporated is a Praxair Surface Technologies company.

Page 4
File: 1.9.1.2-77T
Issue: 011111
Supercedes: M11117
Praxair and TAFA Nickel/Chrome/Moly Wire - 77T
Material Review :
Made exclusively for arc spraying, Praxair and TAFA 77T wire 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. 77T has a chemical composition identical to Alloy C-276.
In addition to showing high corrosion resistance to oxidizing acids, 77T exhibits very good abrasion and metal-to-
metal wear resistance. 77T coatings are well suited for applications in the chemical refining and manufacturing
industries, such as pump casings and valve parts when used with a sealer.
CAUTION : All Praxair and TAFA wires have been optimized for arc spraying. Use of substitute wires usually
Application Review:
Praxair and TAFA 77T wire has proven very effective as a coating material in corrosion environments - both acidic
with a sealer and hot gas corrosion. Weld overlay has been the accepted practice in such cases, but it is
extremely costly. The application of 77T by wire arc spray has proven to be an economical alternative.
Additional applications include chemical pumps and valves; pulp & paper digesters and guide rolls; and fan
blades.
Composition:
Chromium 10.0-20.0%
Molybdenum 10.0-20.0%
Iron 3.0-7.0%
Tungsten 3.0-4.0%
Nickel Balance

Melting Point 2400F(1363C) (approx.)
Max. Service Temp. 1900F (1035C)
Bond Strength 7,000 psi (48.23 MPa) Min

2 2
Coating Weight 0.60 lbs/ft /0.001" (7.2 kg/m /mm)
Macrohardness 35 Rc

2 2
Coverage (wire consumption) 0.9 oz/ft /0.001" (1.10 kg/m /micron)

**** Higher air pressure, and lower amperage with gold nozzle cap gives smallest diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/8835
a a a
Atomizing Air Pressure (PSI) 60 65 65
Nozzle/Positioner (Cross=C; Slot=S) Long C Long C Long C
Arc Load Volts 30-32 29-31 29-31
b b b
Amps 100-300 50-300 50-300
popping.
--------------------------
a
b
Can vary depending on size of workpiece and traverse speed.
Page 3
Finishing:
Deposit thicknesses of up to 0.080" may be finished by turning, but can be machined or ground. In many
applications, finishing is often not necessary.
Hazards:

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-78T
Issue: M11117
Supercedes: K10405
Praxair and TAFA TAFALOY Nickel-

Chrome-Moly Wire - 78T
Material Review:
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. 78T
has a chemical composition identical to Alloy 718.
Thermal sprayed Alloy 718 coatings are increasingly used in aircraft power plant dimensional restoration of
component parts with the same base metal composition. The ability to economically apply these coatings with arc
wire is a major factor in the selection of the repair process.
Application Review:
Alloy 718 wire has proven very effective as a coating material in corrosion environments - both acidic and hot gas
corrosion. Weld overlay has proven effective, but extremely costly. The application of 78T with a sealer has
proven to be an economic alternative.
In addition, flange and "fit up" dimensional restoration with the arc process instead of the more costly plasma and
HVOF options is being aggressively pursued by the OEM aircraft power plant manufacturers.
TAFALOY 78T, coupled with an appropriate sealer, should also be considered for service in many acidic
environments.
TAFALOY 78T meets the following specification: GE Standard Practices Manual #70-49-45, FAA RDE #000-637.
Composition:
Nickel 53
Chromium 18.5
Moly 3
Iron 18.5
Other 7

Melting Point 2400F
Bond Strength 9,000 psi (62 MPa)
Tensile Strength 24,000 psi (165 MPa)
Macrohardness 30 Rc (converted from 335 DPH)

2
Spraying:
2 2


rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/8835
c c c
Secondary --- --- ---
Nozzle/Positioner (Cross=C; Slot=S) Long C Long C Long C
a
Arc Load Volts 30-32 30-32 30-32
b
Amps 100-300 50-300 50-300
popping.
--------------------------
a
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
c
Page 3
Hazards:

www.praxaix.com/thermalspray
Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-79B
Issue: I11229
Supercedes: I10816
Praxair and TAFA Arc Spray Bond Wire79B

Material Review:
79B wire, a unique nickel-aluminum alloy for use in arc spray systems, is available from Praxair and TAFA. The
wire produces superior bond coats that are dense and resistant to high temperature oxidation, thermal shock and
abrasion. The material is equally suitable as a one-coat system; for example, a finish of five (5) microinches is
attainable. This wire is manufactured exclusively for wire arc spraying. The unusual self-bonding ability of the
alloy is attributed to the exceptionally high temperatures the nickel-aluminum reaches and which on impact with
the base material, forms a strong bond. Measured bond strengths have been determined to be 55 percent higher
than those formed by exothermic reactions of nickel and aluminum mixtures -- the previous materials available to
demonstrate such self-bonding characteristics. One of the major problems in achieving high quality, well bonded
coatings in any thermal spray process is the costly, extensive preparation of the substrate. 79B eliminates the
problem. The coating, through extensive testing, has also been found to be superior to exothermic materials in
sharp edge and impact loading.
79B wire is self-bonding to a broad range of smooth metal surfaces including annealed or hardened carbon
steels, annealed or hardened alloy steels, stainless steels, aluminum, nickel, cast iron, titanium and tantalum. It is
not self-bonding to copper based alloys or tungsten. 79B wire can be sprayed with any Praxair and TAFA arc
spray gun.
Praxair and TAFA's 79B meets the following specification = Rolls Royce Omat #3/90A
cause problems such as excessive tip wear, spitting and feeding problems. We only recommend
Praxair and TAFA certified wires.
Application Review:
Arc spray coatings from 0.004 to 0.006 inch (0.01 to 0.015 mm) can be readily applied in one pass. Thicker
coatings up to 0.250 inch (6.3 mm) have been applied by continuous spraying. Thus, in some cases, 79B can be
used as a one-coat system. Coatings can be machined to a rough finish with tungsten carbide tools or ground to
smooth finish with aluminum oxide or silicon carbide wheels. 79B wire can be sprayed directly on a smooth,
chemically clean surface without conventional blasting, turning or roughening, thereby, eliminating the need for
expensive preparation equipment and the associated labor and quality control. However, where possible, the
surface should be prepared by rough cutting (thread), rough grinding, grit blasting (24 mesh steel shot or
aluminum oxide at 80 psig pressure blast) or using a clean coarse emery cloth since this increases bond strength
by an additional 600 psi. In any case, note that the surface to be sprayed must be clean, freshly exposed metal.
Since 79B coatings look like stainless steel, it is cosmetically acceptable to many end users as a finish coat.
Typical properties of the Praxair and TAFA nickel-aluminum arc spray coating when sprayed on a clean but
unroughened (unprepared) steel surface include: bond strength - 9000 psi; with a typical coating hardness of 55-
80 Rb.
Nickel 80 percent
Al 20 percent
Bond Strength Tensile 9,000 psi blasted

b
Coating Texture (as sprayed) Variable (see next page)
Hardness 55-80 Rb
c
2
Magnetic Properties Non-magnetic, slight magnetic susceptibility

-6
Coefficient of Thermal Expansion 7 x 10 in/inF (1000F)
Electrical Resistivity 220 micro ohm cm (approximate)

d
Spraying:

2 2
c
Spray Pattern (approximate 8 inch standoff) Cross Nozzle/Positioner - 1 in (2.5 cm)
a
Values are for steel substrates according to ASTM C633-69.
b
c
Density depends on air pressure - 80 percent "Bond Coat" setting, 90 percent subsequent buildup.
d
No evident nickel alloy/substrate scaling with 0.020 inch coating after:
five days @ 1000, three days @ 1800F, 15 minutes @ 2200F
e
Higher air pressures, smaller wire (1/16), and lower amperage with red nozle cap gi ves smallest
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/8835 8830/8835 9000
c c
Secondary --- 40 60 ---
a
Arc Load Volts 30 30 30-32 30-32
b
Amps 100-300 100-300 100-300 100-300
--------------------------
a
by 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 work piece and traverse speed.
c
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 300F can improve

Finishing:
Surface Speed 1.27 m/s (250 fpm)

Traverse Speed 38 cuts/cm (96 cuts/in) (0.0105 in)
Depth of Cut 250 micon (0.010 in) for first few cuts then 125 micron (0.005 in) to finish
Tungsten carbide tools can be used to obtain a rough finish and grinding to obtain a good smooth finish. Use light
cuts for roughing and finishing. Dress frequently and do not permit coating to overheat.
a problem on the very hardest coatings. However, it is fairly easy to generate a 20-microinch finish using the
correct grinding wheel and grinding technique. A 15-microinch finish can be obtained with care. Secondary
finishing is required below 10 microinch. Grinding must be taken in stages, working down in finish with
successively finer finishing surfaces.
Page 3
Silicon carbide
37 C
I hardness
8 porosity
Wheel rpm: Med/High

Shaft rpm: Low
Secondary finishing with either silicon carbide or diamond cloth using a mineral base (non-sulfur) 5 to 10 weight
320 cloth to remove the marks from the 240 cloth. Then use the 400 --- and so on. If one switches to the finer
A series of a 1/2" diameter shafts were finished at Praxair and TAFA following these principles. The finish on the
79B coated shafts was judged to be "approaching 8 microinches"; i.e., definitely better than 16, but clearly not as
good as 4.

2.5 finish
0.0005 finish 0.0005
Note: See Bulletin 2.7.3.2.5.2 for aircraft rear turbine case machining recommendations (100-150 SFM, 0.008"
feed).
Hazards:
Page 4

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 5
File: 1.9.1.2-80T
Issue: N10817
Supercedes: K10330
Praxair and TAFA Arc Spray 18/8 Stainless

Steel Wire - 80T
Material Review:
Praxair and TAFA's 80T is an 18/8 stainless steel made exclusively for arc spraying. Characteristics of the
coating are its very high corrosion resistance and high shrinkage. However, note that arc sprayed 18/8 coatings
have a lower shrinkage than gas sprayed. Because of high shrinkage it should not be used for coatings over
0.080 inches. Where greater thicknesses are required, it is advisable to first spray 60T-13% chrome steel and
then finish with the higher shrinkage 80T material.
Arc Spray 80T Stainless wire meets Department of Defense Specification MIL-W-6712C, Table I, Stainless 18/8.
Application Review:
Used wherever a coating is required to withstand the higher temperatures needed in place of zinc or chrome steel
and where maximum corrosion protection is desirable. Highly successful results are achieved with 80T as the final
coating to resurfaced paper mill cylinders. Smaller jobs include resurfaced pump plungers, resurfaced impellers,
rams, pump sleeves, shafts, seal rings, casings, valve plugs, wedges, and printing press transfer ink rollers.
BondArc is a registered trademark TAFA Incorporated, Concord, NH

Composition:
Carbon 0.12
Phosphorus Trace
Sulphur Trace
Manganese 1.5
Nickel 8
Chromium 18
Silicon 0.5
Iron Balance

Tensile Bond Strength 4,110 psi (28.3 MPa)

2
Spraying:
2 2


rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
These are starting parameters only. Optimum parameters will vary depending on application,
utilities, environment, spray rate and equipment.
Coating Type
8830/35 8830/35 8850 8850 9000 9000
c c c c c c
c c
Secondary --- 40 --- 60 --- 60
Nozzle Cap Blue * Green Green Green Green
Nozzle/Positioner (Cross=C; Short C ** Long C Long C Long C Long C
Slot=S)
a
Arc Load Volts 29-30 29-30 30-32 30-32 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300 50-300 50-300
Standoff Inches 5-7 3-5 5-7 3-5 5-7 3-5
Coating Thickness/Pass-mils 5 5 5 5 5 5

--------------------------
a
b
c
Page 3

Finishing:
Hazards:
Practices for Thermal Spraying," and AWS TSS-85, "Thermal Spraying, Practice, Theory and Application".
Manual.

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4trademarks of their respective owners.
File: 1.9.1.2-85T
Issue: K10330
Supercedes: I11229
Praxair and TAFA Arc Spray 316 Stainless

Steel Wire - 85T
Material Review:
Praxair and TAFA 85T is a Type 316 Stainless Steel made exclusively for arc spraying. Characteristics of the
coating are its very high corrosion resistance and high shrinkage. However, note that arc sprayed 85T coatings
have a lower shrinkage than when gas sprayed. Because of high shrinkage, it should not be used for coatings
over 0.080 (2mm) inches. Where greater thicknesses are required, it is advisable to first spray 60T-13% chrome
steel and then finish with the higher shrinkage 85T material.
Arc Spray 85T Stainless wire meets Department of Defense Specification MIL-W-6712B, Table I, Stainless 316.
Application Review:
Used wherever a coating is required to provide improved corrosion resistance over 18/5 Stainless Steel (Praxair
and TAFA 55T) or 420 Stainless Steel (Praxair and TAFA 60T). Highly successful results are achieved with 85T
as the final coating to resurfaced paper mill cylinders. Smaller jobs include resurfaced pump plungers, resurfaced
impellers, rams, pump sleeves, shafts, seal rings, casings, valve plugs, wedges, and printing press transfer ink
rollers.
BondArc is a registered trademark TAFA Incorporated, Concord, NH

Composition:
Carbon 0.08
Phosphorus 0.04
Sulphur 0.03
Manganese 2.0
Nickel 12
Chromium 17
Silicon 1.0
Molybdenum 2.5
Iron Balance

Tensile Bond Strength 6,735 psi (46.5 MPa) blasted surface

2
Spraying:
2 2


rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/8835 8830/8835 9000
c c c c
c c
Secondary --- 40 60 ---
a
Arc Load Volts 29-30 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300
minimum noise and smooth arc operation. Excessive voltage causes larger particles and poor
spray pattern. Too low a voltage will cause popping.
NOTE: Standard air caps and positioners can be

used in 8830 or 9000 systems.

--------------------------
a
foot length.
b
c
Page 3
Finishing:
Hazards:
Manual.
Fax: 603-225-4342
Telephone: 1-317-240-2650
4 the Flowing Airstream design and Making our planet more

Praxair,
Page TAFA Incorporated is a Praxair Surface Technologies company.
File: 1.9.1.2-88T
Issue: K10330
Supercedes: I11229
Praxair and TAFA 88T UltraMachinable

Stainless Wire
Material Review:
Praxair and TAFA 88T is a specially developed 300 Series Stainless Steel made exclusively for arc spraying.
Characteristics of the coating are its very high corrosion resistance and excellent machinability. The material is
readily machined, by normal machining methods, to a finish of 20-25 microinch aa. Because of high shrinkage, it
should not be used for coatings over 0.080 (2mm) inches. Where greater thicknesses are required, it is advisable
to first spray 60T-13% chrome steel and then finish with the higher shrinkage 88T material.
Arc Spray 88T UltraMachinable Stainless wire can be sprayed with any Praxair and TAFA Arc Spray gun.
Application Review:
Used wherever a coating is required with excellent machinability and corrosion resistance. Highly successful
results are achieved with 88T as the final coating to resurfaced printing rolls, pump plungers, resurfaced
impellers, rams, pump sleeves, shafts, seal rings, casings, valve plugs and wedges.
Composition:
Specially formulated 300 Series Stainless Steel

Tensile Bond Strength 6735 psi (46.5 MPa) blasted surface
Hardness 93-97 Rb

2
Spraying:

2 2


rough with low psi.
diameter pattern.
Page 2
Spraying Procedure
Coating Type
8830/8835 8830/8835 9000
c c
Secondary --- 40 60 ---
Slot=S)
a
Arc Load Volts 29-30 29-30 30-32 30-32
b
Amps 50-300 50-300 50-300 50-300

--------------------------
a
foot length.
b
c
Page 3
UsePraxair and TAFA's 75 Wire as a Bond Coat:
For additional information on BondArc see Bulletin 1.9.1.2-75B.
Finishing:
The coating gives excellent finishes (20-25 microinch aa) when machined at low speed with carbide tools.
Recommended machining parameters are as follows:
Surface feet/minute: 150-200
Tool Feedrate: 0.001-0.004 inches/revolution
Depth of Cut:
Rough: 0.010-0.020 inches
Finish: 0.001-0.005 inches
Type of Tool Bit: Tungsten Carbide, neutral to positive rake, large radius (0.063-0.125 radius), inclined 10
to 30 degrees from perpendicular, and the cut can be _+ 0.125 inches from center line.
Surface Finish: The surface finish will vary from a very smooth, low porosity finish if machined dry, to a
porous smooth finish if machined with oil. The material cuts very easily with tool life
enhanced once below the initial rough surface. This material demonstrates good chip
development during machining.
Page 4
Hazards:
Manual.

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 5
File: 1.9.1.2-90MXC
Issue: P11205
Supercedes: N10810
Praxair and TAFA 90MXC UltraHard Wire
Material Review:
Made exclusively for arc spraying. This material produces a hard, abrasive and corrosion resistant coating. This
wire has the unique property of increasing hardness after prolonged use. A service environment of up to 1600F
is possible. Conventional grinding and lapping techniques provide high chrome like finishes.
Application Review:
Praxair and TAFA 90XC wire is used primarily as a hard corrosion resistant interface. When applied 0.010 inches
thick, the material exhibits impressive elasticity for a coating this hard. Typical applications use coating
thicknesses up to 0.060 inch.
After application, the coating can be ground using aluminum oxide and subsequently polished to under a 10 RMS
surface finish. This, coupled with good bond strength, high deposit efficiency, low coefficient of friction, high
deposition rates, and ease of application, allows 90MXC coatings to compete with processes that require plating
or plasma technologies.
Praxair and TAFA 90MXC coating application procedures are the same as other Praxair and TAFA hardfacing
wires, and can be applied using the same process parameters.

UltraHard is a registered trademark of TAFA Incorporated, Concord, NH
Composition:
1
ELEMENTS WEIGHT %
Copper 1.9
Silicon 1.1
Chromium 21.0 min.
Nickel 8.0 min.
Manganese 1.25
Boron 2.25
Molybdenum 3.2 min.
Iron Balance

Bond Strength 5100 psi @ 15 mils thick
Macro hardness Approx. 45 Rc
Finish - ground Excellent
Spraying:
2 2
Spray Pattern****(approximate 3-5" standoff) Cross Nozzle/Positioner - 3" (7.6 cm)
1
Compositions are nominal unless otherwise specified

rough with low psi.
diameter pattern.
Page 2
Spraying Procedure
Coating Type
8830/8835 8830/8835 9000
c c c c
c c __
Secondary --- 40 60
a
Arc Load Volts 30-32 30-32 31-33 31-33
b
Amps 100-200 100-200 100-200 100-200

--------------------------
a
b
c
Page 3
Finishing:
Praxair and TAFA 90MXC coatings are usually finished by grinding with an aluminum oxide wheel. Subsequent
polishing can produce a surface finish approaching 10 micro inches (RMS).
Hazards:
Fax: 603-225-4342
Telephone: 1-317-240-2650

Page 4
File: 1.9.1.2-95MXC
Issue: P11205
Supercedes: N10810
Praxair and TAFA 95MXC UltraHard Wire
Material Review:
wire has the unique property of increasing hardness in service. A service environment of up to 1700F is
possible. Conventional grinding and lapping techniques provide high chrome like finishes.
Application Review:
Praxair and TAFA 95XC wire is used primarily as a hard corrosion resistant interface. When applied 0.010 inches
thick, the material exhibits impressive elasticity for a coating this hard. Typical applications use coating
thicknesses up to 0.060 inch.
This material also offers the added advantage of increasing coating hardness to as high as 1180 DPH (Vickers)
after abrasive load is applied.

Composition:
1
ELEMENTS WEIGHT %
Silicon 1.6
Chromium 29.0
Manganese 1.65
Boron 3.75
Iron Balance

Bond Strength 5775 psi (39.82 MPa noiminal) @ 20 mils thick
Microhardness As sprayed: 595 DPH Rc 55

After abrasive load: 1180 DPH
Spraying:
2 2
1

rough with low psi.
diameter pattern.
Page 2
Spraying Procedure
Coating Type
8830/8835 8830/8835 9000
c c c c
c c
Secondary --- 40 60
Nozzle Cap Blue * Blue Blue
Nozzle/Positioner (Cross=C; Slot=S) Short C ** Short C Short C
a
Arc Load Volts 33-34 33-34 33-34 33-34
b
Amps 100-200 100-200 100-200 100-200

--------------------------
a
b
c
Page 3
Finishing:
polishing can produce a surface finish approaching 10 microinches (RMS). Refer to Bulletin 2.1.4.5 for finishing
information.
Hazards:
Fax: 603-225-4342
Telephone: 1-317-240-2650

Page 4
File: 1.9.1.2-96MXC
Issue: 011206
Supercedes: N10810
Praxair and TAFA 96MXC UltraHard

Armacor 16 Wire
Material Review:
Made exclusively for arc spraying. This material produces a dense, hard, low stress abrasion, and high
temperature corrosion resistant coating. This wire has the unique property of increasing hardness in service. A
service environment of up to 1700F is possible. Conventional grinding and lapping techniques provide high
chrome like finishes.
Application Review:
Praxair and TAFA 96XC wire is used primarily as a hard corrosion and abrasion resistant interface. When applied
0.010 inches thick, the material exhibits impressive elasticity for a coating this hard. Typical applications use
coating thicknesses up to 0.050 inch.
This material also offers the added advantage of increasing coating hardness to as high as 1004 DPH (Vickers)
after abrasive load is applied.

ARMACOR products are proprietary to Amorphous Technologies International US Patent 4725512
Composition:
1
ELEMENTS WEIGHT %
Copper 2.15
Nickel 6.20
Silicon 1.23
Chromium 22.5
Manganese 1.0
Boron 2.6
Molybdenum 3.6
Carbon 0.1 max.
Iron Balance
Bond Strength 5500-6000 psi (39.82 MPa noiminal) @ 20 mils thick
Microhardness As sprayed: Rc 53
After abrasive load: 1004 DPH
Spraying:

2 2
1

rough with low psi.
diameter pattern.
Page 2
Spraying Procedure
Coating Type
Normal 8830/8835 9000
c c
Atomizing Air Pressure:Primary 50 60
Secondary --- ---
Nozzle Cap Blue Blue
Nozzle/Positioner (Cross=C; Slot=S) Short C Long C
a
Arc Load Volts 30-32 31-33
b
Amps 100-200 100-200
Standoff Inches 3-5 3-5
Coating Thickness/Pass-mils 5 5
Coating Texture-microinches aa 200-250 200-250
--------------------------
a
foot length.
b
c
Page 3
Finishing:
polishing can produce a surface finish approaching 10 microinches (RMS).
Hazards:
Fax: 603-225-4342
Telephone: 1-317-240-2650

Page 4
File: 1.9.1.2-97MXC
Issue: P11205
Supercedes: 011206
Praxair and TAFA 97MXC UltraHard

DUOCOR Wire
Material Review:
Thermal spray wire utilizing titanium and tungsten carbide within an amorphous matrix to provide excellent
abrasion resistance. Offers very high bond strengths, high hardness, and a non-skid surface.
Application Review:
Praxair and TAFA 97XC wire is used primarily as a hard abrasion resistant interface. When applied 0.010 inches
thick, the material exhibits impressive elasticity for a coating this hard. Applications can use coating thicknesses
up to 0.060 inch for wear and non skid surfaces.

DUOCOR products are proprietary to Amorphous Technologies International
Composition:
1
ELEMENTS WEIGHT %
Silicon 1.25
Chromium 14.0
Nickel 4.5
Manganese 0.55
Boron 1.87
Tungsten Carbide 26.0 min
Titanium Carbide 6.0
Iron Balance

Bond Strength 5100 psi @ 15 mils thick
Macro hardness Approx. 64-69 Rc

1050-1150 DPH300
Spraying:
2 2
1

rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
Normal 8830/8835 9000
c c
Atomizing Air Pressure:Primary 60 60
Secondary --- ---
Nozzle Cap Blue Green
Nozzle/Positioner (Cross=C; Slot=S) Short C Long C
a
Arc Load Volts 30-32 31-33
b
Amps 100-200 100-200
Standoff Inches 3-5 3-5
Coating Thickness/Pass-mils 5 5
Coating Texture-microinches aa 300-400 300-400
--------------------------
a
foot length.
b
c
Page 3
Finishing:
polishing can produce a surface finish approaching 10 micro inches (RMS).
Diamond Wheel finishing is accomplished as follows:
Grit Size 180

Wheel Speed 5500 fpm
Work Speed 100-150 fpm
Removal per cut .003"
Total removal to a 20 RMS finish .012"
Hazards:
Fax: 603-225-4342
Telephone: 1-317-240-2650

Page 4
File: 1.9.1.2-98MXC
Issue: 011206
Supercedes: M10714
Praxair and TAFA 98MXC Chrome Carbide Wire
Material Review:
wire has the unique property of increasing hardness in service. Conventional machining and polishing
techniques provide high chrome like finishes.
Application Review:
Praxair and TAFA 98MXC wire is used primarily as a hard corrosion resistant interface. Typical applications use
coating thicknesses up to 0.060 inch on boiler tubes, food, paper, drums and rolls, shafts in a marine environment
are also sprayed with this material.
After application, the coating can be machined easily with carbide tools and subsequently polished to high RMS
surface finishes. This, coupled with good bond strength, high deposit efficiency, low coefficient of friction, high
This material also offers the added advantage of producing coating hardness of Rc 39-42. The coating is
typically selected where a low coefficent of friction is desired with a balance of abrasion and corrosion resistance.

ELEMENTS WEIGHT%1
Silicon 1.6
Chromium 26.0
Manganese 1.6
Carbon 1.7
Molybdenum 0.8
Nickel 3.0
Iron Balance
1

Bond Strength 5800 psi (39.98 MPa) @ 20 mils thick
Hardness As sprayed: Rc 39-42
Magnetic Yes
Spraying:
Coverage (wire consumption) 1.0 oz/ft2/0.001" (1.2 kg/m2/100 microns)

rough with low psi.
diameter pattern.
Page 2
Spraying Procedure:
Coating Type
8830/8835 8830/8835 9000
Atomizing Air Pressure:Primary 50c 50 c 60 c 60c
Secondary --- 40 c 60 c ---
Nozzle Cap Blue * Blue Blue
Nozzle/Positioner (Cross=C; Short C ** Short C Short C
Slot=S)
Arc Load Voltsa 33-34 33-34 33-34 33-34
Ampsb 100-200 100-200 100-200 100-200
* P/N 450729 8830/8835 Arc Jet Air Cap

--------------------------
a
foot length.
b
c
Page 3
Finishing:
Praxair and TAFA 98MXC coatings are usually finished by machining with carbide tools. Subsequent polishing
can produce a surface finish approaching 10 microinches (RMS). Refer to Bulletin 2.1.4.5 for finishing
information.
Hazards:
Telephone: 603-224-9585
Fax: 603-225-4342
Telephone: 1-317-240-2650
Fax: 1-317-240-2596
Page 4
File: 1.9.1.2-106MXC
Issue: 011206
Supercedes: 010928
Praxair and TAFA Arc Spray Cobalt Alloy -

106 MXC
Material Review:
This material produces coatings which resist wear from abrasive particles, hard surfaces and fretting in high

temperature environments. A coating of 106MXC material can also be used to resist heat and restore parts
made of cobalt or cobalt alloys. The coating is machinable, and significantly harder than Praxair and TAFA's

76MXC . This material can be sprayed with any Praxair and TAFA Arc Spray gun. Praxair and TAFA 106MXC is
being evaluated at several major manufacturers of aircraft engines as a cost-effective alternative to plasma
sprayed materials that conform to PWA 1316 and PWA 1318.
CAUTION: All Praxair and TAFA wires have been optimized for arc spraying. Use of alternate wires may cause
problems such as excessive tip wear, spitting and feeding problems. Please use only Praxair and TAFA certified
wires.
Application Review:
Praxair and TAFA 106MXC is used to produce wear resistant coatings, resist particle erosion at temperatures
from 1000-1550F [540-840C], and is suitable for exhaust valves and seats. Forging tools and hot crushing rolls
are also protected with 106MXC since it is very resistant to indentation from hard surfaces. Mismachined or worn
parts may be rebuilt with 106MXC and remachined. Turbine air seals and turbine vanes coated with 106MXC
withstand fretting in high temperature environments. Other applications include heat treating fixtures, and any
manufacturing equipment that has temperature and erosion environments.

Nickel 10 percent
Chromium 25 percent
Tungsten 8 percent
Carbon 1 percent
Cobalt 56 percent

1
Bond Strength 6700 psi (46 MPa)

2
Coating Texture Variable (see next page)
1
Macrohardness 58-68 Ra
3
Coating Density 7.4 g/cc
Finish
Machined: 40-60 (microinches) Ra
Ground: 10-30 (microinches) Ra
Spraying:
2 2
Spray Pattern ArcJet parameters with primary air at 60 psi (413

kPa) and secondary air pressure at 50 psi (345 kPa)
and a 3" (7.6 cm) standoff produce the smallest
spray pattern.
Length of wire per lb 116 ft. (35.4 m)
1
Depends on air pressure, standoff, nozzle cap and target size.
2
Depends on air pressure - fine with high psi, average with medium psi, and rough with low psi
3
Depends on atomizing air pressure and the use of ArcJet.
Page 2
Spraying Procedure:
Coating Type
8830/35 8830/35 8850 8850 9000 9000
4 4
Atomizing Air Pressure:Primary 50 50-60 60 60-75 60 60
Secondary --- 40-50 --- 50 --- 60
Nozzle Cap Blue ** Green Green Green Green
Nozzle/Positioner Short ** Long Long Long Long
Cross Cross Cross Cross Cross
a
Arc Load Volts 30-32 30-32 32-34 32-34 31-33 31-33
b
Amps 100-200 100-200 100-200 100-200 100-200 100-200
Standoff Inches 3-5 3-5 3-5 3-5 3-5 3-5
Coating Thickness/Pass-mils 5 5 4-5 5 5 5
popping.
required.

--------------------------
4
5
6
Can vary between 50-300 depending on size of the part and traverse speed.
Page 3
Finishing:

Traverse Speed 0.002-0.003" (.05-.08 mm) per rev.
Depth of Cut 0.015-0.025" (.4-.6 mm) for first few cuts then 0.001-0.005" (.03-.13 mm) to finish
Coated tungsten carbide and ceramic tools can be used to obtain a finish of 32 microinches Ra. Grinding can
also be used to obtain a good smooth finish. Dress frequently and do not permit coating to overheat. Cutting oil
is not required. On the hardest coatings, pull out may be a problem if a cutting tool is used, but it is easier to
produce a 20 microinch Ra finish using the correct grinding wheel and grinding technique. A 15 microinch finish
can be obtained with care. Secondary finishing is required below 10 microinches.
Use grinding wheels that meet the following specifications:
Silicon carbide
37 C
I hardness
8 porosity
Wheel rpm: Med/High

Shaft rpm: Low
Amount removed per pass 0.0005 (.013 mm)
Use very light pressure and clean wheel. Super finishing with either silicon carbide or diamond cloth using a
mineral base (non-sulfur) 5 to 10 weight hydraulic oil or kerosene can produce finishes below 10 microinches Ra
by starting with 240 grit paper and progressing to 320, 400 600, 1200, and even 4000. If diamond cloth is
selected, use a 9 to 15 micron particle size. The objective is to use the 240 cloth to completely remove the
grinding marks from the 37 C wheel. Then, use the 320 cloth to remove the marks from the 240 cloth. Each
successive cloth is used to remove the marks from the previous one. If one switches to the finer cloths too soon, a
high polish will result on the "high spots", but many of the original deep grinding marks will remain.

Wheel Speed SFPM 6000 (30 m/s) 6000 (30 m/s)
Work Speed SFPM 60 (.3 m/s) 70 (.36 m/s), rough
Wheel Traverse IPM 7 (3 mm/s) rough 12 (5 mm/s)
2.5 finish (1 mm/s)
In Feed (inches) 0.001 (.025 mm), rough 0.001 (.025 mm)
0.0005 (.013 mm) finish 0.0005 (.013 mm)
Coolant -- Water Soluble, 1 part coolant to 50 parts water
Hazards:
practices, see AWS Publications AWS C2.1-73, chapter 11, "Recommended Safe Practices For Thermal
Spraying" and AWS TSS-85, "Thermal Spraying, Practice, Theory and Application." Thermal spraying is a
completely safe process when performed in accordance with proper safety measures. Become familiar with local
safety regulations before starting spray operations. DO NOT operate your spraying equipment or use the spray
material supplied before you have thoroughly read the Praxair and TAFA Instruction Manual. DISREGARDING
THESE INSTRUCTIONS IS DANGEROUS TO YOUR HEALTH.
Page 4
Fax: 603-225-4342
Telephone: 1-317-240-2650

Page 5
File: 1.9.1.2-204M
Issue: 011206
Supercedes: K10330
Praxair and TAFA TAFALOY Moldmaking

Wire - 204M
Material Review:
TAFALOY 204M wire is made exclusively for Praxair and TAFA's cool spray moldmaking process to create metal
faced tooling. It was developed as a more durable alternative to TAFALOY 200. It has about the same melting
point, a significantly harder surface, and twice the wear characteristics. It sprays about the same as TAFALOY
200, thus, no special care must be taken while spraying.
Application Review:
For many years Praxair and TAFA's moldmaking process has used zinc and tin/zinc type materials to fabricate
metal faced molds. In many cases tool life was finite because of normal handling, abuse when removing parts
and actual surface deterioration in production. Requests for a more durable surface resulted in the development
of TAFALOY 204M wire which resembles Kirksite in performance. It should be selected as a tooling surface
whenever maximum durability and strength is desired. Surface detail reproduction is not as good as
TAFALOY 205 wire but is acceptable for most applications.
Production molds for the manufacture of composites, polyurethane, polyethylene, PVC, ABS, fiberglass and
polycarbonate products have been successfully made. The big advantages over the conventional mold
manufacturing methods are that the speed of producing a mold has greatly increased, the cost has been
considerably reduced and the detail is excellent.
TAFALOY 204M material is widely used to manufacture production spray metal foundry patterns to replace costly
machined aluminum and cast iron patterns.
TAFALOY is a registered trademark of TAFA Incorporated, Concord, NH

Composition:
Kirksite Type

Wire Size 1/16" (2 mm)
Bond Strength 1310 psi blasted surface (9 MPa)
Coating Tensile Strength 14,000 psi (96.5 MPa)

3
Density 6.36 gm/cc
2
Melting Point 792F (approx.)
Shrink 0.001 in/in
Hardness R15T 28-32
Coefficient of Thermal Expansion 10.0 micro-in/in/F
Spraying:
Spray Rate 22 lbs/hr/100 amps
2 2
Coverage (wire consumption) 0.8 oz/ft /0.001" ** (approx.) (0.98 kg/m /100
microns)
Length of wire per lb 70 ft., (2 mm), 113 ft (1/16")
* Ninety-one percent of theoretical at 8 inches. Depends on standoff distance.

** Depends on tool size and geometry, and pattern material.
Page 2
Spraying Procedure
Coating Type
8830/8835 8830/8835 9000
c c c c
Atomizing Air Pressure:Primary 60 50 60 65-75
c c
Secondary --- 40 60 ---
Nozzle/Positioner (Cross=C; Long C ** Long C Long C
Slot=S)
a
Arc Load Volts 20-21 20-21 21-22 21-22
b
Amps 50-300 50-300 50-300 50-300

CAUTION: The most critical time in mold spraying is the first 0.015 inch of shell. Exercise
extreme caution during this phase of spraying, always keep gun moving or substrate rotating.
Keep standoff 10 inches _ + 1 inch. Do not allow master to overheat - realize that heat dissipates
slowly until coating thickness is built up. On small tools there is a greater tendency to overheat,
use back of hand discomfort test to monitor temperature.
--------------------------
a
foot length.
b
c
Page 3
Finishing:
See Praxair and TAFA Bulletin 2.7.2.5.1 for typical surface polishing techniques.
Precautions:
TAFALOY 204M wire fumes are toxic. While spraying, all personnel should be made aware of the need for
complete respiratory protection.
Hazards:
practices, see AWS Publications AWS C2.1-73, "Recommended Safe Practices for Thermal Spraying," and
AWS TSS-85, "Thermal Spraying, Practice, Theory and Application." Thermal spraying is a completely safe

Telephone: 1-317-240-2650 Fax: 603-225-4342

Page 4
File: 1.9.1.2-444MXC
Issue: 010411
Supercedes: 011005
Praxair and TAFA Arc Spray Nickel-Chromium

Molybdenum Aluminum Micromatrix-Composite
Wire - 444MXC
Material Review:
Praxair and TAFA 444MXC is specifically tailored to produce the characteristics of a stainless like material. These
characteristics are wear resistance and excellent corrosion resistance. Hard bearing areas and dimensional
restoration of areas are typical applications.
Praxair and TAFA 444MXC is a unique cored wire product for use in arc spray systems. It is available exclusively
from Praxair and TAFA. Measured bond strengths exceed 6000 psi at 0.020" thickness. Praxair and TAFA
444MXC can be sprayed with any Praxair and TAFA arc spray equipment. In many instances, use of the ArcJet?
is preferred (See Bulletin 1.1.8.4).
Application Review:
Arc spray coatings of 0.004" to 0.006" can be readily applied in one pass.
Thicker coatings up to 0.60" have been applied by continuous spraying.
444MXC can be machined to a 32 microinches (AA) finish using Tungsten
Carbide tools or ground to a smooth finish with aluminum oxide or silicon
carbide wheels. The surface should be prepared by grit blasting (60 mesh
(or coarser depending upon part geometry) aluminum oxide at 60 psig blast
pressure). In all cases the surface to be sprayed must be clean and exhibit
freshly exposed metal. 444MXC is specifically formulated to meet the
following specification: Allison Engine Company specification EMS-56762
Special Properties
Praxair and TAFA 444MXC produces high strength coatings that are readily machineable with low shrinkage and
high bond strength. Applications include salvage and buildup of machineable carbon and stainless steels, particle
erosion and cavitation resistance, fretting and abrasive wear.
MXC and ArcJet are registered trademarks of TAFA Incorporated, Concord, NH

Composition:
Element Nominal %
Chromium 9%
Aluminum 7%
Molybdenum 5.5%
Iron 5.0%
Nickel Balance

Wire Size 1/16 in

a
b
Coating Texture (as sprayed) 550 microinch (AA) attainable
Hardness 65 R15N (95 RB converted)

c
2
Maximum Operating Temperature 1600F (768 C)

-6
Coefficient of Thermal Expansion 7 x 10 in/inF
Corrosion Resistance Excellent
Spraying:
2 2
Spray Pattern (approximate 4" standoff) Cross Nozzle/Positioner - 1 in (2.5 cm)

a
Values are for steel substrates according to ASTM C633-69
b
c
Page 2
A quick comparison between 444MXC and Metco 444:

444MXC M-444
Bond strength (psi)
a. at 0.015-0.020" 6500 5000*
b. 0.060" 4000 N/A
Hardness
a. RB 95 85
b. R15T 91.5
c. DPH300 210
d. KHN 220
a. as sprayed 300-700 300-700
Other properties
a. spray rate (lbs/hr/100 amps) 26.5 6-8(#/Hr. max)
b. coverage (oz/sqft/0.001") 1.0 0.64
c. deposit efficiency 75% 70%
Spraying Procedure
Coating Type
8830/8835 8830/8835 9000
c c c c
c c
Secondary --- 40 60 ---
Slot=S)
5
Arc Load Volts 30-32 30-32 31-33 31-33
b
Amps 100-200 100-200 100-200 100-200

** P/N 620074 ArcJet Modified Short Cross (8830)
--------------------------
a
foot length.
b
c
Page 3
Finishing:

Traverse Speed 0.002-0.003 inches per rev.
Depth of Cut 0.015-0.025 in (250 micron) for first few cuts then 0.001-0.005 in (125 micron) to finish
finishing is required below 10 microinch.
Silicon carbide
37 C
I hardness
8 porosity
Wheel rpm: Med/High

Shaft rpm: Low
hydraulic oil or kerosene can produce finishes below 10 microinches Ra by starting with 240 grit paper and
progressing to 320, 400 600, 1200, and even 4000. If diamond cloth is selected, use a 9 to 15 micron particle
size (obtained from 3M or others).
The objective is to use the 240 cloth to completely remove the grinding marks from the 37 C wheel. Then, use
the 320 cloth to remove the marks from the 240 cloth. Then use the 400 - --- and so on. If one switches to the
finer cloths too soon, a high polish will result on the "high spots", but many of the original deep grinding marks will

2.5 finish
In Feed (inches) 0.001 rough 0.001 (.025 mm)
0.0005 finish 0.0005 (.013 mm)
Page 4
Hazards:
Fax: 603-225-4342
Telephone: 1-317-240-2650

Page 5
File: 1.9.1.2-ALCRO
Issue: Q10507
Supersedes: Q10326
TAFA ARC SPRAY IRON-CHROME-

ALUMINUM WIRE - ALCRO
Material Review:
Made exclusively for arc spraying. This material produces coatings which highly resist corrosive gases in boiler
atmospheres such as vanadium and sulfur and oxidation temperatures up to 1600F. A coating of this material can also
be used to resist heat and prevent oxidation scaling of conventional low alloy steels. The coating is machinable.
The material should be sprayed with Praxair and TAFA's special arc spray boiler coating system.
The ALCRO material is prealloyed, not like composite powders which when plasma sprayed produce significant amounts
of dust leading to coating inclusions and less density. The composite powder also produces cells of different materials
(non-homogeneous) which may lead to localized corrosion and/or spalling.
CAUTION: All Praxair and TAFA wires have been optimized for arc spraying. Use of alternate wires
Usually causes problems such as excessive tip wear, spitting and feeding problems. We only
recommend Praxair andTAFA certified wires.
Application Review:
ALCRO is a solid wire drawn to the FeCrAl composition listed below. This material contains chromium and aluminum for
corrosion resistance and superior bond strength.
Solid wires are much easier to work with both from a feeding and spraying perspective. ALCRO coatings produce highly
machinable coatings that can be machined faster than other thermal spray coatings (generally in the 250 to 550 surface
feet per minute range). ALCRO coatings feather into edges or base metals without noticeable parting lines. Fine finishes
(12-32 RMS) can be achieved using the correct machining parameters, and spraying techniques. ALCRO is a self
bonding material with high bond strengths. Coatings can be built up thicker than .150" per side without much stress build
up. This material/coating is ideally suited to repair mis-machined parts, shafts, bearing fit areas, dies, rolls and journals.
This coating is recommended for those applications that require a machine finish to restore parts having most common
steels as base materials. Common Steels such as 1018, 4140 carbon steel, 200, 300, and 400 series stainless steels,
most tools steels and cast iron.
This material is not as corrosion resistant as TAFALOY 45CT but in certain less aggressive environments may prove
more cost effective. It produces superior adhesive bond strengths (7000+ psi) when sprayed with Praxair and TAFA's
specially designed arc spray system. Praxair and TAFA's system with ALCRO produces cooler, extremely low thermal
shock coatings which can be used for patching older type plasma coatings more effectively than plasma or gas wire
guns.
This material, when sprayed with nitrogen, produces an extremely desne, high conductivity, low oxide content coating
which could be used for on-site spraying of resistive heater elements or strips on ceramics.
1.9.1.2-ALCRO
Composition:
Aluminum 4.2 - 5.3 percent
Silicon 0.65 maximum
Chromium 20.5 - 23.5 percent
Iron Balance

Deposit Efficiency 82 percent *
Melting Point 2770 F (1520C)

Coating Texture 300-350 microinches AA

Machrohardness 230 Knoop100 (Rb 88)
Coating Weight 0.0375 lbs/ft2/mil
Finish, machined: Fair

ground: Good
Resistance: 783 ohms/mil/ft2 (68F)
Coefficient of Expansion: 14.1x10-6 in/in/C (20-800C)
Spraying:
Coverage (wire consumption) 0.8 oz/ft2/0.001" (0.98 kg/m 2/100 micron)

Length of wire per lb 104 ft (1/16")
* Depends on gas pressure and standoff
2
1.9.1.2-ALCRO
Spraying Procedure:
Coating Type
Normal Arc Jet Arc Jet

8830/8835 8830/8835 9000 9000
Atomizing Air Pressure:

Primary 50c 50c 60c 60c
-- --
Secondary 40c 60c -- --
Arc Load Volts a 29-30 29-30 30-32 30-32
Amps b 50-300 50-300 50-300 50-300
Thickness/Pass-mils 5 5 5 5
Texture-microinches aa 200-350 150-250 150-250 200-350
will cause popping.

_______________________
a
increase by approximately 3.4 volts per 50 ft. of extension; i.e., add 3.4 volts to the recommended
b
c
3
1.9.1.2-ALCRO
Finishing:
ALCRO is usually finished by machining or grinding. Machining gives a fair finish and grinding gives a good
finish.
Hazards:
Chrome is under investigation in the welding industry as a toxic substance. Full respiratory protection should
be used when spraying this material.
Publication AWS C2.1-73, "Recommended Safe Practices for Thermal Spraying" on general spray practices
and AWS TSS-85, "Thermal Spraying, Practice, Theory and Application". Thermal spraying is a completely
safe process when performed in accordance with proper safety measures. Become familiar with local
safety regulations before starting spray operations. DO NOT operate your spraying equipment or use the
spray material supplied before you have thoroughly read the TAFA Instruction Manual.
workpiece preparation and operator technique. TAFA warrants only that the wires are free of defects in
material and workmanship. No other warranty is expressed or implied.

Telephone: 603-224-9585
Fax: 603-225-4342
Telephone: 1-317-240-2650

4
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If you have any questions, please call your Regional Sales Manager.

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Wire Solutions

Praxair Surface Technologies, Inc. and TAFA

Whether your application calls for a reliable bond coat,

When you search for the right thermal spray wire,

Cored wire advantages

Application of cored wire technology

Praxair and TAFAs complete family of Arc Spray Systems offers

8830 8835 BP400

9000 Spare Parts Contact Tips

In todays competitive marketplace, improved productivity and

They require a company like Praxair, North Americas largest

As your single-source supplier, Praxair can help reduce your

Fax: All product photographs are not to scale and should

Coverage values and Spray Rates are estimates

Thermal spray coatings produced by wire-based

The information contained herein is offered for use

Printed in the United States of America

Praxair and TAFA Arc Spray Silicon

Coating Physical Properties

Deposit Efficiency 69 Percent*

Melting Point 1080F (583C) (approx.)

Bond Strength 3,787 psi on low carbon steel (63.6 Mpa)

Texture (as machined) 40-80 (microinches aa)*, **

Hardness - macrohardness R15T 84 (RB 72 converted)

Shrink 0.0068 in/in (cm/cm)

Porosity Less than 2 percent

* P/N 450729 8830/8835 Arc Jet Air Cap

environment, spray rate and equipment.

DISREGARDING THESE INSTRUCTIONS MAY BE DANGEROUS TO YOUR HEALTH.

Copyright 2000 Praxair Technology, Inc. All rights reserved www.praxair.com/thermalspray

Telephone: 1-317-240-2650 Fax: 603-225-4342

Other trademarks used herein are trademarks or registered

Printed in the United States of America 05-2000

Praxair and TAFA Arc Spray Silicon Aluminum Wire - 01S

* P/N 450729 8830/8835 Arc Jet Air Cap

DISREGARDING THESE INSTRUCTIONS MAY BE DANGEROUS TO YOUR HEALTH.

Copyright 2000 Praxair Technology, Inc. All rights reserved www.praxair.com/thermalspray

Telephone: 1-317-240-2650 Fax: 603-225-4342

Other trademarks used herein are trademarks or registered

Printed in the United States of America 05-2000

Praxair and TAFA Arc Spray Aluminum Wire - 01T

Material Review: marine and similar environmental exposures. For

Length of wire per lb 282 ft (1/16"), 176 ft (2 mm)

2. Use proper power supply tap - see previous

Aluminum is the most difficult of all wires to spray

A high quantity of dust is produced and a minimum

Aluminum or magnesium substrates should be

A variety of finishes can be achieved through

general spray practices, see AWS Publications AWS Telephone: 1-317-240-2650

A Material Safety Data Sheet will be sent with each

DISREGARDING THESE INSTRUCTIONS MAY BE Telephone: 603-224-9585

TAFA is constantly improving its products, therefore specifications are

Praxair and TAFA TAFALOY 02A

Coating Physical Properties

Deposit Efficiency 70 Percent**

Melting Point 440C(approx.)

Bond Strength 3,680 psi blasted steel surface (25.4 MPa)

Hardness R15T 85 (RB 73) Converted from Knoop100

Shrink 0.002 in/in (cm/cm)

* P/N 450729 8830 Arc Jet Air Cap

DISREGARDING THESE INSTRUCTIONS MAY BE DANGEROUS TO YOUR HEALTH.

Copyright 2000 Praxair Technology, Inc. All rights reserved www.praxair.com/thermalspray

Telephone: 1-317-240-2650 Fax: 603-225-4342