Issued October 2000 Supersedes June, 1982

TM

Metco 402 Self-Bonding Stainless Wire

Technical Bulletin #10-007

Metco 402 Self-Bonding Stainless Wire

Metco 402 is a stainless steel, nickel, aluminum composite wire. It was especially developed to produce thin, self-bonding, hard stainless type coatings, with good wear resistance and good corrosion and oxidation resistance properties, for wear resistance and hard bearing applications. Metco 402 is ideally suited for many thin coating applications, such as buildup of lathe ways, salvage of mismachined parts and maintenance of machine element bearing surfaces. Metco 402 can be considered as an alternative to Metcoloy 2 Stainless and Sprabond for thin coating applications. Metco 402 offers two major advantages: High-Integrity coatings and One-Step spraying. One-Step coatings offer these benefits: Eliminate the need for a separate bond coat. Less undercutting required. The allowance for a bond coat thickness is eliminated. Less technique dependence. Reducing the number of steps required to produce the coating also reduces the chance of error. More convenience. One-step coatings eliminate having to change materials and spraying parameters. Metco 402 was designed to produce hard, moderate-shrink, high-strength coatings which are recommended for applications requiring resistance to abrasive wear, fretting, cavitation, particle erosion, and for the salvage and buildup of grindable corrosion resistant steels and grindable carbon steels. This revision of the bulletin has been issued to correct spray data coverage information and to reduce lighting pressures for the 2XT Extension with the Type 10E and 3K Guns. This reduction in gas pressures has been made to minimize potential lighting problems.

Features
The properties of the coatings produced with Metco 402 provide a number of additional benefits: High Bond Strength - Typical coating tensile bond strengths are 3300 psi (2275 N/cm2) on a ground low carbon steel substrate. Good Wear Resistance - Resistance to abrasive wear is equal to coatings of Sprabond and 70% that of Metcoloy 2 coatings. Good Scuff Resistance - Scuff resistance properties are better than Metcoloy 2 coatings. High Interparticle Cohesion - Coatings exhibit excellent internal strength which provides high tensile strength over 27,850 psi (19,200 N/cm2), and good edge retention for grinding.
#10-007 Metco 402 Self-Bonding Stainless Wire 2

Hard Coatings - Typical macrohardness is Rc30. Good Corrosion Resistance - Coatings exhibit excellent oxidation resistance in temperatures up to (427C) 800F. Good Finishing Capability - Coatings can be ground to a good finish. Ground finishes are equal to ground finishes of Metcoloy 2 or Sprabond. Metco 402 Wire can be sprayed with most Metco Flame Spray Guns. It cannot be sprayed with the Type 7E, 9E and 11E Guns, since these high speed units cannot be slowed down to the 31/2 feet per minute feed rate required.

Applications
Coatings of Metco 402 are recommended for the following applications: Coating No. M402-10 M402-10 Coating Function Hard Bearing Surfaces Resist Abrasive Grains (Low Temperature) Resist Hard Surfaces (Low Temperature) Resist Fretting (Intended Motion) Resist Fretting (No Intended MotionLow Temperature) Salvage & Buildup on Grindable Carbon Steel Salvage & Buildup on Grindable Corrosion Resistant Steels Typical Applications Bearing journals, fuel pump rotors, sleeves Cylinder liners, pistons, pump plungers, hydraulic rams, crankshaft bearings Wire drawing capstans, pump seals, mechanical seals Machine bedways, wear rings Press fits, bearing seats

M402-10

M402-10 M402-10

M402-10

Mismachined parts, worn parts

M402-10

Mismachined parts, worn parts

Coating Selection
Coating M402-10 is produced with a Type 10E and 12E Flame Spray Gun and Type 3K and Type 5K Flame Spray Machines.

Typical Wire Characteristics

Typical Composition: Nickel Aluminum Iron Chromium 52% 20% 20% 4%
3

#10-007

Metco 402 Self-Bonding Stainless Wire

Typical Wire Size:

Other Elements 4% 1 /8" Diameter Approximately 0.024 lbs/ft (33.5 g/m)

Typical Physical Properties of the Coatings

M402-10 650-800 16.5-20 10-20 .25-.5 Rc30 335 5.7 2% 8% .030 .57 27,850 19,200 3,300 2,275 Moderate

Texture, as-sprayed (microinches aa): (microns): ground, 60 grit SiC (microinches aa): (microns): Macrohardness: Cross Sectional Hardness (DPH300): Density (g/cc): Porosity (Volume %): Oxide Content (Volume %): Coating Weight (lb/ft2/.001"): (kg/m2/0.1mm): Tensile Strength (Perpendicular to the direction of spray), psi: N/cm2: Bond Strength, Low Carbon Steel, ground, psi: N/cm2: Shrink Rate:

Shrink Rate
Moderate shrinkage is typical for coatings for Metco 402 due to the nature of the alloying elements and the high cohesive strength of the coating. The shrinkage rate is higher than Metcoloy 2 or Sprabond coatings.

Thickness Limitation
Coatings of Metco 402 are generally recommended for thin coating applications. Coatings have been successfully applied as follows: Thickness Limitation (Substrate Preparation): Round* (ground) Flat (ground) Round* (Blasted with Metcolite C) Flat (Blasted with Metcolite C)

(1.3mm) (0.6mm) (2.5mm) (1.3mm)

0.050" 0.025" 0.100" 0.050"

*Applied on 2" (50.8mm) diameters. As diameter increases, thickness limitation decreases. Grit blasting or other surface preparation techniques increases thickness capability.

#10-007

Metco 402 Self-Bonding Stainless Wire

Bond Strength
Metco 402 is similar to Metco 405 Nickel Aluminide in that the self-bonding property is a direct result of an exothermic reaction. The resultant heat from the exothermic reaction provides high bond strength, and also causes better interparticle bonding which results in greater coating integrity. On ground substrates of low carbon steel, bond tests conducted in accordance with ASTM C 633 indicate that self-bonding tensile strengths of 3,000 psi (2275 N/cm2) are typical. In order to produce Metco 402 coatings with the best bonding characteristics and thickness capability, the recommended spraying parameters must be followed. The critical parameters include preheat temperature, workpiece cooling, and spray distance. Excessive preheating (above 185F) and spray distances, closer than recommended, should be avoided as these reduce thickness capability and contribute to the formation of high internal coating stresses. Metco 402 coatings will not reliably self-bond to base metals made of copper and some high copper alloys, molybdenum or tungsten.

Internal Coating Strength

Coatings of Metco 402 exhibit excellent internal strength as a result of high interparticle cohesion.

Wear Resistance
Standard aluminum oxide-oil slurry wear resistance tests show the wear resistance of Metco 402 coatings to be better than Metco 405 nickel aluminide coatings and equivalent to Metco Sprabond coatings. Metco 402 coatings exhibit approximately 70% of the wear resistance of Metcoloy 2 coatings.

Corrosion Resistance
Metco 402 coatings show fair corrosion resistance, and are equivalent in this capacity to Metcoloy 2 coatings.

Scuff Resistance
Overall friction and galling characteristics of Metco 402 coatings against hardened steel surfaces are better than those exhibited by Metcoloy 2 coatings and somewhat less than that exhibited by Sprabond coatings.

Maximum Service Temperature

Stagnant air furnace tests have established that the maximum recommended temperature of Metco 402 is (427C) 800F.

Surface Preparation
Coatings of Metco 402 are self-bonding to ground, grit blasted or machined surfaces. Grit blasting or other surface preparation techniques increases the upper limit of the thickness capability.
#10-007 Metco 402 Self-Bonding Stainless Wire 5

In all instances, the substrate must be thoroughly cleaned. Surface oxidation must be removed, and preheating is required to prevent the formation of condensate. Metco 402 coatings have been successfully ground to a feather edge. For such applications, it is recommended that the substrate be roughened by at least grit blasting.

Spraying
To produce Metco 402 coatings with their outstanding characteristics, the recommended spraying parameters must be followed. Excessive spray rates or spray distances shorter than recommended will inhibit the exothermic reaction needed to produce the excellent bond and internal strength. Metco 402 Self-Bonding Stainless Wire can be sprayed with Metco Type 10E, 12E, 3K and 5K Flame Spray Guns, using acetylene, propane and MPS as fuel gases. Metco 2XT and 3XT Extensions can also be used giving satisfactory results. Follow the equipment and spray parameter recommendations published in this bulletin and in the Type 12E and 5K Gun Instruction Manuals. Spray distance, spray rate, and preheat temperature are important. Excessive preheat should be avoided to assure proper bonding. Preheat Temperature: (65-85C) 150-185F Typical Application Rate: .002 per pass (.05mm) Spray Distance: See Spray Tables Also refer to Volume I of the Metco Flame Spray Handbook for information regarding spraying techniques.

Spray Data
Deposit Efficiency Coverage Wire Required Coating Weight 75% 125 sq. ft./hr. at .001" thick .040 lbs./sq. ft. at .001" thick 0.030 lbs./ft2 at .001" thick

Wire Spraying Speed

The proper spraying speed is obtained at just below the point where the wire sputters. The spray stream will be at its fullest density at this point. Care should be taken in handling the wire in that excess bending or a kink in the wire could result in damage to the wire and spitting in the coating. Special rear wire strain relief guides, designed for use with Metco 405 Wire, are available to prevent binding or kinking of Metco 402 Wire while spraying. Metco 402 Wire comes packaged in a protective cardboard box, wound on a disposable reel, to prevent damage during shipping and general handling.

Finishing
Metco 402 Wire coatings show excellent grinding characteristics. Finishes can be obtained which are
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superior to Sprabond coatings and about equal to wire sprayed Metcoloy 2 coatings. Coatings of Metco 402 are best finished by grinding. Excellent finishes have been obtained by grinding using a 60 grit silicon carbide wheel number GC60-H11-VR. Good finishes have also been obtained using coarse grit aluminum oxide wheels.

Cylindrical Grinding
Wheel No.: Wheel Speed: C46-K4-VE 5500-6500 ft./min. (1650-1950 m/min.) 50-70 ft./min. (15-21 m/min.) 70-100 ft./min. (21-30 m/min.) .25"-.50"/rev. (6.4-12.7mm/rev.) .08"-.17"/rev. (2.-4.3mm/rev.)

Surface Work Speed, Roughing: Finishing:

Traverse Speed, Roughing: Finishing:

Surface Grinding
Wheel No. Wheel Speed: Crossfeed, Roughing: Finishing: Table Speed: GC60-H11-VR 5500-6500 ft./min. (1650-1950 m/min.) .06"-.125" (1.6-3.18mm) .015"-.03" (.38-.76mm) 40-100 ft./min. (12-30 m/min.)

Safety Measures
Flame spraying is a completely safe process when performed in accordance with Metcos Safety Measures. Familiarize yourself with local safety regulations before starting spraying operations. DO NOT operate your spraying equipment or use the spray material supplied before you have thoroughly read the Metco Instruction Manual. Disregarding These Instructions May Be Dangerous To Your Health

#10-007

Metco 402 Self-Bonding Stainless Wire

#10-007

Gun EC EC EC EC EC EC EC EC EC EC EC EC C C C 30 50 40 15 50 40 70 70 70 40 61 55 32 27 25 50 52 54 5 5 5 35 55 55 15 45 50 65 70 70 52 70 70 40 32 32 43 43 43 6 6 7 6 6 5 Note 2 Note 2 Note 2 35 55 55 15 45 50 70 75 75 52 70 70 40 32 32 50 51 51 5 5 6 6 6 5 108 182 177 108 182 177 76 150 122 45 55 55 15 50 50 60 70 70 52 70 70 42 32 32 42 43 43 6 6 7 5 5 5 117 177 177 43 34 35 44 32 35 44 32 35 30 29 25 45 55 55 15 50 50 70 75 75 52 70 70 42 32 32 50 51 51 5 5 6 5 5 5 117 177 177 43 34 35

Fuel Gas

Nozzle

Air Cap

PSI Lighting Pressure Oxy. Fuel Air

Flowmeter Readings* (Note 1) Oxy. Fuel Air

Spray Distance Inches

Consumption Per Hour Wire Cu. Ft. Cu. Ft. lbs./hr Oxy. Fuel

10E

Acet. Prop. MPS

7A-1/8 7A-1/8P 7A-1/8M

Spraying Table - U.S. System

3K

Acet. Prop. MPS

7A-1/8 7A-1/8P 7A-1/8M

12E

Acet. Prop. MPS

7-48 7-49 7-25

5K

Acet. Prop. MPS

7-48 7-49 7-25

Metco 402 Self-Bonding Stainless Wire

2XT w/10E (Note 3) (Note 4) C C C 30 50 40 15 50 40 65 65 65 40 61 55 32 27 25 42 42 42

Acet. Prop. MPS

7A-1/8 7A-1/8PH 7A-1/8MH

2XT w/3K (Note 3) (Note 4)

Acet. Prop. MPS

7A-1/8 7A-1/8PH 7A-1/8MH

5 5 5

Note 2 Note 2 Note 2

76 150 122

30 29 25

NOTES: 1. Flowmeter readings are for use with Metco Type 2GF and 2AF Flowmeters. 2. Proper spraying speed is obtained at just below the point where the wire sputters. The spray stream will be at its fullest density at this point. 3. Values of pressure and flow are based on the (900mm) 3 foot extension. When using other extension lengths, lower fuel and oxygen pressures to obtain flow readings shown. 4. When angular spraying, use pressure and flow readings for appropriate gun and fuel listed above. Use a non-loading 1/8 nozzle and 2XT 16-1/8 air cap for all fuel gases.

#10-007

Gun EC EC EC EC EC EC EC EC EC EC EC EC 2.07 3.45 2.76 1.03 3.45 2.76 4.8 4.8 4.8 40 61 55 32 27 25 50 52 54 130 130 130 2.41 3.8 3.8 1.03 3.1 3.45 4.48 4.8 4.8 52 70 70 40 32 32 43 43 43 150 150 180 2.7 2.7 2.3 Note 2 Note 2 Note 2 2.41 3.8 3.8 1.03 3.1 3.45 4.8 5.17 5.17 52 70 70 40 32 32 50 51 51 130 130 150 2.7 2.7 2.3 3.1 5.2 5.1 3.1 5.2 5.1 2.2 4.2 3.5 3.1 3.8 3.8 1.03 3.4 3.4 4.1 4.8 4.8 52 70 70 42 32 32 42 43 43 150 150 180 2.3 2.3 2.3 3.3 5.0 5.0 1.2 .96 .99 1.2 .91 1.0 1.2 .91 1.0 .85 .82 .71 3.1 3.8 3.8 1.03 3.4 2.8 4.8 5.2 5.2 52 70 70 42 32 32 50 51 51 130 130 150 2.3 2.3 2.3 3.3 5.0 5.0 1.2 .96 .99

Fuel Gas

Nozzle

Air Cap

Bars Lighting Pressure Oxy. Fuel Air

Flowmeter Readings* (Note 1) Oxy. Fuel Air

Spray Distance mm

Consumption Per Hour Wire Cu. Meter Cu. Meter kg/hr Oxy. Fuel

10E

Acet. Prop. MPS

7A-1/8 7A-1/8P 7A-1/8M

3K

Acet. Prop. MPS

7A-1/8 7A-1/8P 7A-1/8M

Spraying Table - Metric System

12E

Acet. Prop. MPS

7-48 7-49 7-25

5K

Acet. Prop. MPS

7-48 7-49 7-25

Metco 402 Self-Bonding Stainless Wire

2XT w/10E

(Note 3) (Note 4)

Acet. Prop. MPS

7A-1/8 C 7A-1/8PH C 7A-1/8MH C

2XT w/3K

(Note 3) (Note 4)

Acet. Prop. MPS

7A-1/8 C 7A-1/8PH C 7A-1/8MH C

2.07 3.45 2.76

1.03 3.45 2.76

4.5 4.5 4.5

40 61 55

32 27 25

42 42 42

130 130 130

Note 2 Note 2 Note 2

2.2 4.2 3.5

.85 .82 .71

NOTES: 1. Flowmeter readings are for use with Metco Type 2GF and 2AF Flowmeters. 2. Proper spraying speed is obtained at just below the point where the wire sputters. The spray stream will be at its fullest density at this point. 3. Values of pressure and flow are based on the (900mm) 3 foot extension. When using other extension lengths, lower fuel and oxygen pressures to obtain flow readings shown. 4. When angular spraying, use pressure and flow readings for appropriate gun and fuel listed above. Use a non-loading 1/8 nozzle and the 2XT 16-1/8 air cap for all fuel gases.

The information provided in this document is for the convenience of Sulzer Metcos 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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