File:

1.9.1.2-ALCRO

Issue: Supersedes:

Q10507 Q10326

TAFA ARC SPRAY IRON-CHROMEALUMINUM 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.

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Composition:
Aluminum Silicon Chromium Iron 4.2 - 5.3 percent 0.65 maximum 20.5 - 23.5 percent Balance

Coating Physical Properties

Wire Size Deposit Efficiency Melting Point Bond Strength Coating Texture Machrohardness Coating Density Coating Weight Porosity

1/16" (1.6 mm) 82 percent * 2770 F (1520C) 7000 psi (53.6 MPa) 300-350 microinches AA 230 Knoop100 (Rb 88)

7.1 gm/cc
0.0375 lbs/ft2/mil Less than 1 percent Fair Good 783 ohms/mil/ft2 (68F) 14.1x10-6 in/in/C (20-800C)

Finish, machined: ground: Resistance: Coefficient of Expansion:

Spraying:
Spray Rate Coverage (wire consumption) Spray Pattern****(approximate 8" standoff)

11 lbs/hr/100 amps (5 kg/hr/100 amps) 0.8 oz/ft2/0.001" (0.98 kg/m 2/100 micron)
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 * Depends on gas pressure and standoff

104 ft (1/16")

1.9.1.2-ALCRO

Spraying Procedure:
Coating Type Normal 8830/8835 Atomizing Air Pressure: Primary Secondary Nozzle Cap Nozzle/Positioner Arc Load Volts a Amps b Standoff Inches Thickness/Pass-mils Texture-microinches aa 50c
-- --

Arc Jet 8830/8835 50c 40c * ** 29-30 50-300 5-8 5 150-250

Arc Jet 9000 60c 60c Green Long Cross 30-32 50-300 5-8 5 150-250

9000 60c -- -Green Long Cross 30-32 50-300 5-7 5 200-350

Blue Short Cross 29-30 50-300 5-7 5 200-350

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 P/N 620074 8830 Arc Jet Air Cap Arc Jet Modified Short Cross (8830 & 9000)

_______________________
a

b c

When using power lead extensions other than the normal 12 foot furnished, the voltage must be increase 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. Can vary between 50-300 depending on size of workpiece and traverse speed. For finer finish, raise air pressure at point of finish.

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. 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 TAFA Instruction Manual. 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. 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.praxairthermalspray.com psti-info@praxair.com Telephone: 1-317-240-2650 Fax: 1-317-240-2596 Praxair, the Flowing Airstream design and Making our planet more productive are trademarks or registered trademarks of Praxair 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

www.tafa.com psti-info@praxair.com Telephone: 603-224-9585 Fax: 603-225-4342 TAFA is constantly improving its products, therefore specifications are subject to change without notice TAFA Incorporated is a Praxair Surface Technologies company.