Thermal Spray Wire - Bondcoats, Bondrite® Thermal Spray Wire

Thermal Spray Materials

Thermal Spray Wire

Plasma Powders

Thermal Spray Wire
Plasma Powders and Systems Inc offers wires for almost every thermal spraying venture. We are known around the world for our 1/8" 80/20 NiAl Bondrite but also provide Aluminum Bronze, Babbit, Copper, Aluminum, Tin, Zinc, Zinc/Aluminum, 202 Stainless Steel, 420 Stainless Steel, Molybdenum and many others. We offer wire sizes in 11 and 15 Gauge, 1/16", 1/8" and 3/16” but are not limited to them. Our wires are available in spools, coils, or payoff packs to best fit the needs of the customer. If you do not see the wire you are looking for please give us a call at #732-431-0992 and we will do our best to provide you with the materials you need.

228 Boundary Road
PO Box 132
Marlboro, NJ 07746
Phone 732-431-0992
Toll Free: 800-358-4287

BONDRITE® 1/8" dia. Ni-Al Bonding Wire

Plasma Powders and Systems Bondrite® is one of the leading bondcoats in the thermal spray industry. Our solid nickel core with an aluminum coating creates a solid spray with no “spitting”, a common flaw in other bondcoat wires. This allows for an even spray and finish when using Bondrite®.

Thermal Spray Wire, Bondrite NI Al Bonding Wire

Specification:	A composite Nickel-Aluminum wire to spray as a bondcoat in the Oxy-Acetylene wire-spray metallizing process. Typically 80% Ni and 20% Al.
Physical Appearance:	A bright Aluminum tubular wire containing a solid Nickel core wire.
Bond Strength:	As per lab reports, there was a failure of the adhesive in all three samples, one slightly below 12,000 p.s.i. and two well above 12,000 p.s,i, with a 0.009" coating.
Coating Appearance:	A 200X micro of a 0.005" coating of BONDRITE bondcoat over a steel substrate shows excellent alloying at the interface.
Advantages:	This wire sprays at a higher speed of about 8 lbs per hour compared to 5 lbs for the currently available Ni-Al wire and gives an extremely homogeneous spray pattern. Also unlike the wire with petletized Nickel powder core inside an Aluminum tube, this wire does not spit. The older wire had a tendency to propel un-melted Nickel particles if the Aluminum sheath burned out prematurely. This does not happen with BONDRITE as the solid Nickel wire cannot shoot out unless it is melted and atomized by the compressed air jet before it is sprayed. This in turn imparts very high bond strength to the coating, as proven by the lab report.
Packaging:	The wire is layer wound on 12" diameter spools with a weight of 11 lbs each. Special packaging is available at no additional cost for a reasonable quantity if requested at the time of placing the order.

Lab Results

Bondrite Tensile Specimens

0.009" Coating Thickness

#	Sample ID	LBS	PSI	Failure Mode
1	1	9111	11606	100% Adhesive Failure
2	2	9100	11592	100% Adhesive Failure
3	3	9529	12139	100% Adhesive Failure
	Avg Failure	9247 lbs	11779 psi

NOTE 1: All three coatings specimens outlasted the maximum strength of the adhesive. No Coating Failures occurred on any of the specimens.
NOTE 2: Specimens were machined from 3 separate panels.

Tests were performed by Protech Lab Corp. on July 24th of 2009. Adhesive Utilized: EC2086 (3M Adhesive)