ISSUE: 9/94-9

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2.3.12

METALLISATION WIRE 75E

NICKEL ALUMINIUM

APPLICATIONS

Primarily used as a self-bonding coat where extensive and expensive preparation

of the substrate is neither possible nor desirable. 75E is self-bonding to a wide
range of smooth metal surfaces, including steels, stainless steels, cast iron,
titanium, tantalum and aluminium. It is not self bonding to copper or tungsten. The
pre-alloyed wire produces superior bond coats that are: dense, resistant to high
temperature oxidation, thermal shock and abrasion. The excellent density and
adhesion allows the "feather edging" of coatings which further reduces preparation
costs.

In some cases, 75E can be used as a one coat system or as a composite with
steels, etc. Since 75E looks like stainless steel, it is cosmetically acceptable to
many users as a finish coat.

WIRE DETAILS

Wire Size : 1.6mm

Composition : A complex nickel-aluminium alloy

PHYSICAL PROPERTIES OF COATING*

Adhesion : Tensile 28.96 MPa (4,200 psi) on clean,

unprepared steel.
33.09 MPa (4,800 psi) on blasted surface

In Shear 103.42 MPa (15,000 psi) on blasted

surface
64.12 MPa ( 9,300 psi) on clean, unprepar-
-ed steel.
Melting Point : 1650°C + (3000°F +)
Density : 6.9 gm/cc
Hardness : 200 Knoop
20-25 Rc
170-200 Hv
155-165 Hb

* The physical properties shown over page are given as a guide only. In
practice, the values achieved are dependent on the spraying parameters,
the equipment used, surface preparation etc.

___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.3.12
customers and Metallisation Ltd. accept no liability arising from its use.
© Metallisation Limited Page 1 of 3
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2.3.12

TYPICAL PERFORMANCE FIGURES

Throughput : 5.8 Kg/hr/100A

Efficiency : 70%
Weight of wire required : 0.92 Kg/m²/100µ

TYPICAL SPRAYING PARAMETERS

a) Combustion Gas Spraying

75E does not exhibit the same self-bonding characteristics when gas
sprayed and therefore this method is not recommended.

b) Electric Arc Spraying

Metallisation Arc Spray Pistols : 240 and 528

Metallisation Spraying Heads : CG16
Air Pressure : 4.4 - 5.1bar
Voltage : 29-30 V
Spray Distance : 15-18 cm (6-7 in)
Current : 175 Amp1.
1 Typical for 5-12cm (2-5 in) diameters, higher currents can be used for
larger work pieces but should be limited to 300A.

FINISHING

An exceptionally good finish can be achieved by turning.

Surface Speed : 1.27 m/s (250 fpm)

Traverse Speed : 38 cuts/cm (263µ) (96 cuts/in (0.0105"))
Depth of Cut : 125µ (0.005") for first few cuts then 250µ (0.001")
to finish

75E coatings may be ground to a smooth finish with aluminium oxide or silicon
carbide wheels.

Do not permit the coating to overheat.

SPEEDS AND DRY GRINDING WET GRINDING

FEEDS
Wheel Speed 30 m/s (6000 fpm) 30 m/s (6000 fpm)
Work Speed 0.3 m/s (60 fpm) 0.35 m/s (70 fpm)
Wheel Traverse 2.96 mm/s (7 ipm) rough 5.08 mm/s (12
1.06 mm/s (2. ipm)
5 ipm) finish
In Feed 25µ (0.001") rough 25µ (0.001") rough
12µ (0.005") finish 12µ (0.0005")
finish
___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.3.12
customers and Metallisation Ltd. accept no liability arising from its use.
© Metallisation Limited Page 2 of 3
 7(&+1,&$/%8//(7,1
2.3.12

PRECAUTIONS

Observe normal spraying practices, respiratory and hearing protection should be

provided. UV eye protection should be worn when arc spraying.

___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.3.12
customers and Metallisation Ltd. accept no liability arising from its use.
© Metallisation Limited Page 3 of 3