Issued March 2002

Sulzer Metco

Sulzer Metco 8234

Aluminum 12%
Silicon Alloy Wire

Technical Bulletin #10-675

 Sulzer Metco 8234 Aluminum 12% Silicon Alloy Wire
Introduction

Sulzer Metco 8234 is an excellent general purpose aluminum-silicon alloy wire that was developed
for use in the salvage and build-up of components made of aluminum or magnesium and their alloys
using the electric arc spray process. Sulzer Metco 8234 produces coatings that are harder and
slightly denser than both commercially pure aluminum and Metco SF Aluminum AW but somewhat
less corrosive resistant. Sulzer Metco 8234 coatings are easily machined to a much finer finish than
coatings of pure aluminum making this material an excellent choice for dimension restoration.

Sulzer Metco 8234 is recommended for low temperature applications as the physical properties of
aluminum-silicon alloys change over time at higher temperatures due to “aging” that is a result of the
precipitation and growth of the silicon nodules. Studies have found a decrease in hardness after
exposure to temperatures of 315° C (600° F) for 24 hours. Machinability of the coating is adversely
affected by the decrease in hardness, resulting in poorer finishes.

Typical Applications

Sulzer Metco 8234 is recommended for use in the following areas:

• Machine element repair/restoration of dimension
• Aircraft inlet cases
• Seal area and flange repairs on gearboxes

Typical Wire Properties

Chemical composition (weight %):

Aluminum 88
Silicon 12

Wire size: 14 ga. (1.6 mm, 0.064” diameter)

Typical Sulzer Metco 8234 Coating Characteristics - SmartArc® (100-200 Amps)

Air Cap: Fine Fine

Primary Air Pressure, psi: 35 60
Secondary Air Pressure, psi: 0 0

Surface Profile:
As-Sprayed,
Micrometers Ra: 15.3-16.5 11.4-13.9
Microinches Ra: 600-800 450-550
Machined,
Micrometers Ra: 1.0-1.5 1.0-1.5
Microinches Ra: 40-60 40-60

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Typical Sulzer Metco 8234 Coating Characteristics - SmartArc (100-200 Amps) (cont’d)

Air Cap: Fine Fine

Hardness:
1
Macrohardness: Rh 96-99 Rb 55-59
3

Bond Strength (ASTM C-633):

2

“C” Grit Blasted Steel,

MPa: >68 >61
Psi: >10,000 >9,000
3
Density, g/cm : 2.3 2.3

Coating Thickness Limits:

3

“C” Grit Blasted Steel,

mm: >1.27 >1.27
inch: >0.050 >0.050

Coating Weight:
kg/m2 x 0.1mm: 0.23 0.23
lb/ft2 x 0.001”: 0.12 0.12

1
Superficial hardness (R15T) taken and converted.
2
Bond strength data may vary depending on the type of adhesive used and sample preparation.
3
Thickness limitations presented above are flat substrates, however, coatings thicker than 2.5 mm
(0.100”) have been sprayed on shafts without evidence of spalling or cracking.

Coating Photomicrographs - SmartArc (200 Amps)

Fig. 1 Sulzer Metco 8234 SmartArc sprayed

at 60 psi on a shaft (x100).

#10-675 Sulzer Metco 8234 Aluminum 12% Silicon Alloy Wire 3

Recommended Finishing Procedures

Machining is the recommended finishing procedure for Sulzer Metco 8234 coatings. Excellent finishes
have been produced using a “D” shape tungsten carbide tool bit, with the work rotating at 185 surface
feet per minute (0.94 m/s), a traverse of 0.06 mm (0.025”) per revolution, and an in-feed of 0.05mm
(0.002”). No lubricant was used. Wet machining, using a lubricant suitable for aluminum, should also
produce satisfactory results.

Safety Recommendations

The Material Safety Data Sheet (MSDS) contains hazard and other information specific to each product
and is available upon request. Sulzer Metco 8234 is intended for use in the thermal spray process.
Thermal spray operators must be trained on the proper operation of the spray equipment to be used
and hazards present. Avoid breathing process dust and fumes. If it is necessary for the operator to be
close to the thermal spray process during operation, protective clothing, gloves, eye protection, hear-
ing protection and a respirator must be worn, as required. In addition, the spray area must always be
equipped with a suitable exhaust and dust collection system designed for fine metal powders. Dust
and over spray should not be allowed to accumulate in the spray area and should be cleaned up regularly.

Storage Requirements

Store wire in a clean, dry location preferably in the original packaging. Wire must be protected from
physical damage as kinks and blends could render the wire unsuitable for use. Avoid rough handling
and dropping as this could cause tangles leading to feeding difficulty.

Recommended Sulzer Metco 8234 Parameters - SmartArc (100-200 Amps)

The below spray parameters are starting points only. Additional information can be customized for
your specific needs by calling our Applications Development Department.

Air Cap: Fine Fine

Air Pressure:
Primary, bar: 2.4 4.1
psi: 35 60
Secondary, bar: 0 0
psi: 0 0

Power Settings:
Voltage: 26-28 26-28
Amperage: 100-200 100-200

Hourly Consumption:
100 Amps
kg. Wire: 2.5 2.5
lb. Wire: 5.5 5.5

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Recommended Sulzer Metco 8234 Parameters - SmartArc (100-200 Amps) (cont’d)

Air Cap: Fine Fine

Hourly Consumption:
200 Amps
kg. Wire: 4.1 4.1
lb. Wire: 9.0 9.0

Spray Distance:
mm: 102-152 102-152
inch: 4-6 4-6

Wire Clamping Pressure:

bar: 1.2 1.2
psi: 20 20

Front Roller Type: Serrated Serrated

Deposit Efficiency, %: 55-60 60-65

Wire Required:
kg/m2 x 0.1mm: 0.385 0.385
lb/ft2 x 0.001”: 0.020 0.020

Coverage:
100 Amps
m /hr x 0.1mm/hr:
2
6.5 6.5
ft2/hr x 0.001”/hr: 276 276
200 Amps
m /hr x 0.1mm/hr:
2
10.7 10.7
ft2/hr x 0.001”/hr: 451 451

The information provided in this document is for the convenience of Sulzer Metco’s customers for the
purpose of evaluation and proper use of the Sulzer Metco product(s) described herein. This document
and the information contained herein is the property of Sulzer Metco and shall not be used, disclosed,
or reproduced in whole or in part for any purpose other than for the use of said product(s). Nor shall
this information be used in any way with goods not manufactured and sold by Sulzer Metco. Sulzer
Metco makes no warranties, express or implied, as to the information contained herein.

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