WIRE FLAME SPRAY GUN
METALLIZING EQUIPMENT.
Metaflux Spray Solutions manufactures wire flame spray guns — also called metallizing guns or metalizing pistols — in Pimpri-Chinchwad, Pune, India, for applying zinc and aluminium corrosion-protection coatings to steel structures, bridges, tanks and pipelines.
What Is Wire Flame Spray?
Wire flame spray feeds a solid metal wire into an oxy-fuel flame. The wire melts at the nozzle and a compressed air jet atomises the molten metal onto a grit-blasted substrate, building a dense mechanically bonded coating. Because the substrate stays cool, there is no distortion and no change to the base metal.
In India the process is more often called metallizing. Also known as a metallizing gun, metalizing pistol, or wire spray gun — the equipment on this page is the same thing under all of those names, and is used for zinc and aluminium anti-corrosion coating on bridges, penstocks, storage tanks, structural steel and pipelines, and for dimensional restoration of worn shafts and bearing housings.
METALLIZING GUN MODELS.
Handheld Wire Flame Spray Gun
Handheld metallizing gun for on-site zinc and aluminium coating of structures, tanks and pipework. Pneumatic wire drive, no external power needed at the nozzle.
Automated Wire Metallizing System
Electric wire drive built for robot and manipulator integration. Consistent wire feed for continuous production metallizing lines.
TYPICAL
SPECIFICATIONS.
Typical operating data for handheld and automated wire flame spray (metallizing) guns. Exact specifications vary by configuration — request a datasheet for the model you are evaluating.
| Parameter | Typical Range |
|---|---|
| Wire Diameter | 2.0 / 2.5 / 3.17 mm (also 1/8 in) |
| Wire Materials | Zinc, Aluminium, Zn-Al 85/15, Copper, Bronze, Babbitt, Molybdenum, Stainless Steel |
| Fuel Gas | Acetylene, LPG / Propane or MAPP |
| Oxygen Consumption | 1.5 – 3.0 m³/hr |
| Fuel Gas Consumption | 0.7 – 1.5 m³/hr |
| Compressed Air | 40 – 75 m³/hr (24 – 45 CFM) at 4 – 5 bar |
| Spray Rate — Zinc | 9 – 14 kg/hr |
| Spray Rate — Aluminium | 3 – 5 kg/hr |
| Spray Rate — Stainless Steel | 3 – 6 kg/hr |
| Spray Distance | 150 – 250 mm |
| Coating Thickness Per Pass | 50 – 150 microns |
| Gun Weight (Handheld) | 2.5 – 4.0 kg |
| Wire Drive | Pneumatic turbine or electric (automated models) |
FREQUENTLY ASKED
QUESTIONS.
The questions buyers and maintenance engineers ask most often about wire flame spray and metallizing guns.
What is a metallizing gun?
A metallizing gun is the common Indian name for a wire flame spray gun, also called a metalizing pistol or wire spray gun. It feeds a solid metal wire into an oxy-fuel flame, melts the wire at the nozzle, and a compressed air jet atomises the molten metal onto a grit-blasted surface. Metaflux Spray Solutions manufactures handheld and automated metallizing guns in Pimpri-Chinchwad, Pune.
What is the difference between wire flame spray and arc spray?
Wire flame spray melts a single wire in an oxy-fuel flame, while twin wire arc spray melts two wires with an electric arc struck between them. Wire flame spray guns are lighter and need only gas cylinders and compressed air, which suits site and in-situ work; arc spray deposits faster — typically 15 to 30 kg/hr on zinc against 9 to 14 kg/hr for wire flame spray — but needs an electrical power source. Metaflux Spray Solutions manufactures both.
Which wire materials can a wire flame spray gun apply?
A Metaflux wire flame spray gun applies zinc, aluminium, Zn-Al 85/15, copper, bronze, babbitt, molybdenum and stainless steel wire in 2.0, 2.5 and 3.17 mm diameters. Zinc, aluminium and Zn-Al are used for corrosion protection on structural steel, bridges, penstocks and tanks. Babbitt and bronze are used for bearing shells, and steel and molybdenum are used to rebuild worn shafts and housings.
What compressed air supply does a metallizing gun need?
A wire flame spray gun typically needs 40 to 75 m³/hr (24 to 45 CFM) of clean, oil-free and moisture-free compressed air at 4 to 5 bar. The air does the atomising, so an undersized or wet air supply is the most common cause of a coarse, porous metallizing coating. The exact figure depends on the gun model and air cap fitted.
How much does a metallizing gun cost in India?
Metaflux Spray Solutions quotes metallizing gun prices on request, because the price depends on the model, whether the wire drive is pneumatic or electric, and the gas control and spare parts package supplied with it. Send the wire material, wire diameter and expected duty through the enquiry form on this page and Metaflux returns a written quotation from Pune.
Does Metaflux Spray Solutions supply wire flame spray equipment outside India?
Yes. Metaflux Spray Solutions supplies thermal spray and metallizing equipment across India and to customers in the Middle East. Enquiries from other regions are handled case by case — contact +91 72399 92555 or Info@metafluxspraysolutions.com.
Wire Flame Spray Applications
and Coating Materials.
Zinc / Zn-Al
Bridges, penstocks, tanks, structural steel.
Aluminium
Marine and high-temperature TSA duty.
Babbitt / Bronze
Bearing shells and journal restoration.
Steel / Moly
Rebuilding worn shafts and housings.