Wire Choices




Wires come to the head of the gun, are melted by the welder, and the molten metal is sprayed by the air compressor.

Zinc Aluminum Wire (85/15)

85% zinc - 15% aluminum wire combines the best attributes of pure zinc with the benefits of pure aluminum in the metalized coating.

It is very often used as a substitute for pure zinc because it is somewhat more chloride and sulfur dioxide resistant than pure zinc, while retaining the greater electro-chemical activity of pure zinc.


Aluminum Wire

Sprayed aluminum is preferred for use in industrial environments, especially where there are high concentrations of sulfur dioxide and other pollutants. Arc sprayed aluminum has a relatively high bond strength even over marginally prepared surfaces.

Aluminum pH range is 4 to 11.

At elevated temperatures up to about 1100° F (590° C); for example, on the fire-side of fossil fuel boiler tubes.

Applications include steel pilings above and below the mud and water lines; in marine atmospheres, offshore oil platforms, ship chain lockers, fish holding tanks.


Zinc Wire

Zinc provides greater galvanic protection than aluminum. Its greater galvanic power protects gaps in the coating better than pure aluminum. It is marginally easier to spray pure zinc than pure aluminum by some flame or arc spray systems.

Zinc pH range is 6 to 12.

Zinc is used in combination with galvanizing to avoid double dipping, and for general repair of galvanized steel.

Zinc should not be used in immersion service at temperatures above 140° F (60° C).


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