aws c2 25 thermal spray feedstock.pdf

7/25/2019 aws c2 25 thermal spray feedstock.pdf

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Specification forThermal SprayFeedstockSolidand CompositeWire and CeramicRods

AWS C2.25/C2.25M:2002An American National Standard

right American Welding Societyded by IHS under license with AWS

Not for Resaleproduction or networking permitted without license from I HS


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550 N.W. LeJeune Road, Miami, Florida 33126

AWS C2.25/C2.25M:2002An American National Standard

Approved byAmerican National Standards Institute

April 23, 2002

Specification for

Thermal Spray Feedstock

Solid and Composite Wire

and Ceramic Rods

Prepared byAWS C2 Committee on Thermal Spray

Under the Direction of AWS Technical Activities Committee

Approved byAWS Board of Directors

AbstractThis specification provides the as-manufactured chemical composition classification requirements for solid and compos-ite wires and ceramic rods for thermal spraying. Requirements for standard sizes, marking, manufacturing, and packag-ing are included.

Key Words Thermal spray, feedstock, ferrous,nonferrous, ceramic rod, chemicalcomposition, solid and compositewires



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Statement on Use of AWS American National StandardsAll standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society are voluntary consensus standards that have been developed in accordance with the rules of the AmericanNational Standards Institute. When AWS standards are either incorporated in, or made part of, documents that areincluded in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carrythe full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by thegovernmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all

cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards.Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be byagreement between the contracting parties.

International Standard Book Number: 0-87171-656-9

American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126

2002 by American Welding Society. All rights reservedPrinted in the United States of America

AWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether spe-cial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on thisstandard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is not undertaking to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the adviceof a competent professional in determining the exercise of reasonable care in any given circumstances.

This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.

Publication of this standard does not authorize infringement of any patent. AWS disclaims liability for the infringementof any patent resulting from the use or reliance on this standard.

Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

On occasion, text, tables, or figures are printed incorrectly (errata). Such errata, when discovered, are shown on theAmerican Welding Society web page (www.aws.org) under Technical in the Departments column.

Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in writ-ing, to the Managing Director Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126(see Annex B). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards maybe rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. Theseindividuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpre-tations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS C2 Committee on Thermal Spray. It must be reviewed everyfive years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations, additions, ordeletions) and any pertinent data that may be of use in improving this standard are required and should be addressed toAWS Headquarters. Such comments will receive careful consideration by the AWS C2 Committee on Thermal Sprayand the author of the comments will be informed of the Committee s response to the comments. Guests are invited toattend all meetings of the AWS C2 Committee on Thermal Spray to express their comments verbally. Procedures forappeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the TechnicalActivities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeuneRoad, Miami, FL 33126.

Photocopy Rights

Authorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, oreducational classroom use only of specific clients, is granted by the American Welding Society (AWS) provided that theappropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400;online: http://www.copyright.com.



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iii

Personnel

AWS C2 Committee on Thermal Spray

E. Rybicki, Chair The University of TulsaT. Call, 1st Vice Chair Power Spray, Inc.

M. Bhusari, 2nd Vice Chair Praxair Surface Technologies E. Mitchell, Secretary American Welding Society

* M. Alan Brookhaven National LaboratoryC. C. Berndt SUNY

R. S. Brunhouse, Jr. A&A Co., Inc.*T. Bernecki BIRL, Northwestern University

M. R. Dorfman Sulzer Metco R. A. Douty Westinghouse Electric Co.

R. O. Drossman Wear Management Services, Inc.* R. J. Dybas General Electric Co.* D. Filippis Plasma Coating Corp.G. L. Fillion Wall Colmonoy Corp.* R. H. Frost Colorado School of Mines

S. Goodspeed Miller Thermal, Inc. A. J. Grubowski Naval Sea Systems Command

D. Hale INEEL* E. S. Hamel Norton Co. J. O. Hayden Hayden Corp.* J. Herbstritt Puget Sound Naval Shipyard

R. Holdsworth ABS Industrial Verification D. A. Lee Stoody Deloro Stellite, Inc.

R. L. McCaw Naval Surface Warfare Center Carderock Division R. McGrann SUNY Binghamton H. Novak USBI Co. United Technologies

* E. R. Novinski Sulzer Metco (Westbury)S. Rangaswamy Wall Colmonoy Corp.

L. Russo SUNY at Stony Brook K. Sampath Concurrent Technologies Corp.

* E. R. Sampson TAFA Praxair M. F. Smith Sandia National Lab R. A. Sulit, Sulit Engineering* J. Streeter Chilean Navy

* R. H. Unger TAFA Praxair*T. H. Via Via Technologies

* J. Watson Hard Face Welding and Machine* J. Wen Shenyang Polytechnic University

M. Wixson Thermion Metallizing Systems J. B. C. Wu Deloro Stellite Co., Inc.

*Advisor



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iv

AWS C2J Subcommittee on Surfacing Materials for Thermal Spraying

J. B. C. Wu, Chair Deloro Stellite Co., Inc. R. A. Sulit, Vice Chair Sulit Engineering

E. F. Mitchell, Secretary American Welding SocietyC. Arata Anval Inc.

G. A. Croopnick Amphorous Technologies International M. R. Dorfman Sulzer-Metco

R. A. Douty Bechtel Bettis LaboratoryG. L. Fillion Wall Colmonoy Corp.

F. J. Hermamek Praxair Thermal Spray B. Mosier Polymet Corp.

**C. L. Null Naval Sea Systems Command*S. Rangaswamy Colmonoy Corp.

* E. Sampson TAFA Praxair J. L. Scott Devasco International, Inc.

E. R. Stevens Fisher Controls International* R. D. Thomas, Jr. R. D. Thomas and Co.

L. T. Vernam AlcoTec Wire Co.

*Advisor

**Correspondence



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v

Foreword

(This Foreword is not a part of AWS C2.25/C2.25M:2002, Specification for Thermal Spray FeedstockSolid and Composite Wire and Ceramic Rods , but is included for information purposes only.)

Thermal spray users following this specification may decide in many, but not all, cases that a thermal spray wire orceramic rod from one manufacturer is interchangeable with that from another. The classification tests permit identificationof similar thermal spray wires and ceramic rods.

This specification was developed pursuant to a request from the U.S. Army Material Technology Center to incorporateMIL-W-6712C, Metallizing Wire , as an American Welding Society Standard.



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vii

Table of Contents

Page No.

Personnel .................................................................................................................................................................... iiiForeword .......................................................................................................................................................................v

List of Tables ............................................................................................................................................................. viii List of Figures ........................................................................................................................................................... viii

1. Scope.....................................................................................................................................................................1

2. Reference Documents ...........................................................................................................................................1

3. Significance and Use.............................................................................................................................................1

4. Basis of Classification...........................................................................................................................................2

5. Certification...........................................................................................................................................................2

6. Test Methods and Retest ......................................................................................................................................26.1 Chemical Analysis ........................................................................................................................................26.2 Retest ............................................................................................................................................................2

7. Method of Manufacture.........................................................................................................................................8

8. Standard Sizes .......................................................................................................................................................8

9. Finish and Uniformity ...........................................................................................................................................8

10. Standard Packaging Forms....................................................................................................................................910.1 Coils with Support ........................................................................................................................................910.2 Spools............................................................................................................................................................910.3 Ceramics Rods ............................................................................................................................................10

11. Winding Requirements........................................................................................................................................1011.1 Winding.......................................................................................................................................................1011.2 Cast and Helix.............................................................................................................................................10

12. Solid and Composite Wire and Ceramic Rod Identification ...............................................................................11

13. Packaging ............................................................................................................................................................11

14. Marking of Packages...........................................................................................................................................1214.1 Product Information....................................................................................................................................1214.2 Precautionary Information .............. ............... ............... ............... .............. ............... ............... ................ ..12

Nonmandatory Annexes ..............................................................................................................................................13 Annex A Guide to Ventilation and Personnel Protection During Thermal Spraying ...............................................13 Annex B Technical Inquiries ....................................................................................................................................17



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viii

List of Tables

Table Page No.

1 Chemical Composition Requirements for Solid Ferrous Thermal Spray Wires............................................32 Chemical Composition Requirements for Solid Nonferrous Thermal Spray Wires......................................43 Chemical Composition Requirements for Cored Composite Thermal Spray Wires .....................................64 Chemical Composition Requirements for Thermal Spray Ceramic Rods .....................................................75 Standard Sizes for Thermal Spray Wires .......................................................................................................96 Standard Sizes for Thermal Spray Ceramic Rods..........................................................................................97 Standard Packaging Dimensions and Weight for Thermal Spray Wires......................................................10

List of Figures

Figure Page No.

1 Thermal Spray Feedstock Classification System Format ..............................................................................82 Dimensions of Standard 12- and 14-in. [300- and 350-mm] Spools ...........................................................113 Dimensions of Standard 22-, 24-, and 30-in. [560-, 610-, and 760-mm) Spools.........................................12A1 Arc Spraying 85/15 Zn/Al on the Interior of a 7-ft Diameter Steel Water Pipe

Over the Missouri River, 1998 .............. ............... .............. ................ ............... ................ .............. ............. 15



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AWS C2.25/C2.25M:2002

1

1. ScopeThis specification prescribes requirements for the

classification of ferrous and nonferrous solid and com-posite wires and ceramic rods as manufactured, for ther-mal spraying.

Safety and health issues and concerns are beyond thescope of this standard and, therefore, are not fully ad-dressed herein. Some safety and health information isavailable from other sources, including, but not limitedto, ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes , and applicable federal and state regulations.

This specification makes use of both U.S. CustomaryUnits and the International System of Units (SI). Themeasurements are not exact equivalents; therefore, eachsystem must be used independently of the other withoutcombining in any way when referring to thermal-sprayfeedstock and the deposited coating. The specificationwith the designation C2.25 uses U.S. Customary Units.The specification C2.25 M uses SI Units. The latter areshown within brackets [ ] or in appropriate columns intables and figures.

2. Reference DocumentsThe following ASTM 1 standards are referenced in the

mandatory sections of this document:(1) ASTM E 29, Standard Practice for Using Signifi-

cant Digits in Test Data to Determine Conformance withSpecifications

(2) ASTM E 34, Test Method for Chemical Analysisof Aluminum and Aluminum Alloys (referee)(3) ASTM E 227, Standard Method for Optical Emis-

sion Spectrometric Analysis of Aluminum and Aluminum Alloys by the Point-to-Plane Technique

1. ASTM standards can be obtained from American Society of Testing and Materials, 100 Barr Harbor Drive, West Consho-hocken, PA 19428-2959.

(4) ASTM E 354, Test Method for Chemical Analysisof High-Temperature, Electrical, Magnetic, and Other Similar Iron, Nickel, and Cobalt Alloys

(5) ASTM E 363, Methods for Chemical Analysis of Chromium and Ferrochromium

(6) ASTM E 536, Test Method for Chemical Analysis

of Zinc and Zinc Alloys(7) ASTM E 926, Test Method for Preparing Refuse-

Derived Fuel (RDF) Samples for Analysis of Metals(8) ASTM STP 747, New Analytical Techniques for

Trace Constituents of Metallic and Metal Bearing Ores(9) ASTM STP 944, Chemical Analysis of Metals

(10) ASTM DS-56/SAE HS-1086, Metals and Alloysin the Unified Numbering System

The following AWS 2 standard is referenced in themandatory sections of this document:

(1) ANSI Z49.1, Safety in Welding, Cutting, and Al-lied Processes

The following ISO3 standard is referenced in the man-

datory sections of this document:(1) ISO 544, Filler Materials for WeldingSize

Requirements

3. Significance and UseThis specification defines the as-manufactured chemi-

cal composition classification requirements for solid andcomposite wires and ceramic rods for thermal spraying.Requirements for standard sizes, marking, manufactur-ing, and packaging are included.

2. AWS standards can be obtained from Global EngineeringDocuments, 15 Inverness Way East, Englewood, CO 80112-5776, Telephone (800) 854-7179, (303) 397-7956, Fax (303)307-2740, Internet www.global.his.com.3. ISO standards can be obtained from American NationalStandards Institute, 11 West 42nd Street, New York, NY10036-8002.

Specification for Thermal Spray FeedstockSolid and Composite Wire and Ceramic Rods



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AWS C2.25/C2.25M:2002

2

This specification may be used to classify and procuresolid and composite wire and ceramic rods for thermalspraying.

4. Basis of Classification4.1 The thermal-spray solid and composite wires, and ce-ramic rods in this specification are classified using a sys-tem that is independent of U.S. Customary Units and theInternational System of Units (SI). The classification isaccording to chemical composition of the thermal-spraymaterial as specified in Tables 1 through 4. Table 1 liststhe chemical composition of solid ferrous wires. Table 2lists the chemical composition of solid nonferrous wires.Table 3 lists the chemical composition of the mixture of the sheath and core material of composite wires. Table 4lists the chemical composition of ceramic rods.

4.2 The system for classifying the thermal-spray feed-stock under this AWS standard is using W, CW, and CRas the prefix designation for solid-alloy and solid-composite wires, cored-composite wires, and ceramicrods respectively, followed by the chemical compositionin decreasing percentage order (see Figure 1).

4.3 Thermal-spray solid and composite wires and ceramicrods classified under one classification shall not be classi-fied under any other classification in this specification.

5. Certification5.1 The act of placing the C2.25 specification and classi-fication designations on the packaging enclosing theproduct, or the classification on the product itself, consti-tutes the suppliers (manufacturers) certification that theproduct meets all of the requirements of the specification.

5.2 The only testing requirement implicit in this certifi-cation is that the manufacturer has actually conductedthe tests required by the specification on material that isrepresentative of that being shipped and that material metthe requirements of the specification. Representative ma-terial, in this case, is material from any production run of that classification using the same formulation. Certifica-tion is not construed to mean that tests of any kind werenecessarily conducted on samples of the specific material

shipped. Tests on such material may or may not havebeen conducted. The basis for the certification requiredby the specification is the classification test of represen-tative material cited above, and the ManufacturersQuality Assurance Program.

5.3 For the purpose of determining conformance with thisspecification, an observed or calculated value shall berounded to the nearest unit in the right-hand place figuresused in expressing the limiting values for quantities in ac-

cordance with the round-off method given in ASTM E 29,Standard practice for Using Significant Digits in TestData to Determine Conformance with this Specification.

6. Test Methods and Retest

6.1 Chemical Analysis6.1.1 The chemical compositions of ferrous and non-

ferrous solid and composite wire and ceramic rod feed-stock are defined in Tables 1, 2, 3, and 4. The chemicalcomposition shall be determined by emission spectro-chemical analysis, inductively coupled plasma spectros-copy, and wet chemical analysis, singly or incombination, in accordance with one or more of the fol-lowing standards, or as agreed to by the purchaser andsupplier:

(1) ASTM E 34, Test Method for Chemical Analysisof Aluminum and Aluminum Alloys (referee)

(2) ASTM E 227, Standard Method for Optical Emis-sion Spectrometric Analysis of Aluminum and Aluminum

Alloys by the Point-to-Plane Technique(3) ASTM E 354, Test Method for Chemical Analysis

of High-Temperature, Electrical, Magnetic, and Other Similar Iron, Nickel, and Cobalt Alloys

(4) ASTM E 363, Methods for Chemical Analysis of Chromium and Ferrochromium

(5 ASTM E 536, Test Method for Chemical Analysisof Zinc and Zinc Alloys

(6) ASTM E 926, Test Method for Preparing Refuse- Derived Fuel (RDF) Samples for Analysis of Metals

(7) ASTM STP 747, New Analytical Techniques for

Trace Constituents of Metallic and Metal Bearing Ores(8) ASTM STP 944, Chemical Analysis of Metals

6.1.2 The sampling for chemical analysis shall be for:(1) Solid Wires. A representative sample obtained

from each heat during pouring or subsequent processing.(2) C ored Composite Wires and Ceramic Rods. A rep-

resentative sample obtained from a melt or a firing of arepresentative sample (melt button) of a lot of the prod-uct manufactured at the same time. The chemical compo-sition can be determined by other than a melt button or asagreed by the purchaser and supplier.

6.1.3 The sample shall be analyzed by accepted ana-

lytical methods. For elements not covered by the abovelisted test methods, the referee test method per ASTME 34, shall be used or as otherwise agreed upon betweenthe manufacturer and the purchaser.

6.2 Retest

6.2.1 If the results of any test fail to meet the require-ment, that test shall be repeated twice. The results of bothretests shall meet the requirements. Specimens for retestmay be taken from the original sample. For chemical



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AWS C2.25/C2.25M:2002

3

T a b l e

1

C h e m

i c a l

C o m p o s i

t i o n

R e q u

i r e m e n

t s f o r

S o

l i d F e r r o u s

T h e r m a l

S p r a y

W i r e s

C 2 . 2 5

C l a s s

i f i c a

t i o n

U N S

N u m

b e r ( 2

) C o m m o n

N a m e

A l l o y

C o m p o s i

t i o n , W e i g h

t P e r c e n t

( 1 )

C

C r

F e

M n

M o

N i

P

S i

S

O t h e r s

A m o u n t

W - F e C - 1

W - F e C - 2

W - F e C - 3

W - F e C - 4

W - F e C - 5

G 1 0 0 9 0

H 1 5 2 2 0

G 1 0 2 0 0

G 1 0 7 5 0

G 1 0 8 0 0

C a r

b o n

S t e e l

( 3 )

1 0 1 0

0 . 0 8 0 . 1

5

0 . 1 5 0 . 2

3

0 . 1 8 0 . 2

8

0 . 8 0

0 . 5 0 0 . 9

0

R e m

R e m

R e m

R e m

R e m

0 . 2 0 0 . 6

0

1 . 0 1 . 5

0 . 3 0 0 . 6

0

0 . 7 0

0 . 4 0 0 . 9

0

0 . 0 4 5

0 . 0 4 5

0 . 0 4 0

0 . 0 4 5

0 . 3 5 0 .

1 0

0 . 0 5 0

0 . 0 5 0

0 . 0 3 0

0 . 0 5 0

W - F e C r M n

W - F e C r C

W - F e N

i C r

T 8 7 5 1 5

T 8 7 5 1 0

T 8 7 5 2 0

A l l o y

S t e e l

( 4 )

1 . 0

1 . 0

0 . 1 0

1 . 6 2 . 0

1 . 3 5 1 . 6 5

1 . 0 2 . 0

R e m

R e m

R e m

1 . 7 2 . 0

0 . 2 5 0 . 4

0

2 . 5 0

0 . 1 5 0 . 2

5

1 . 0 3 . 0

3 . 7 5 . 0

0 . 0 1 0

0 . 0 2 0

0 . 0 3 0

0 . 3 5 ( 6 )

0 . 5 0

0 . 3 5 ( 6 )

0 . 0 4 0

0 . 0 2 0

0 . 0 3 0

T i

0 . 1 1 0 . 1

5

W - F e C r N

i - 1

W - F e C r N

i - 2

W - F e C r N

i - 3

W - F e C r N

i - 4

W - F e C r N

i - 5

W - F e C r N

i - 6

W - F e C r N

i - 7

W - F e C r N

i - 8

W - F e C r N

i - 9

S 3 0 4 8 1

S 3 0 2 8 0

S 2 0 2 8 1

S 2 0 2 8 0

S 3 1 6 8 0

S 3 1 6 8 3

S 3 1 6 8 1

S 4 1 6 8 3

S 4 2 0 8 0

S t a i n l e s s

S t e e l

( 5 )

3 0 4

2 0 2

3 1 6

3 1 6 L

3 1 6 L S i

4 2 0

0 . 0 8 0

0 . 1 2 0

0 . 1 5 0

0 . 0 6 0

0 . 0 8 0

0 . 0 3 0

0 . 0 3 0

0 . 0 3 0

0 . 3 0 0 . 4

0

1 8 2

0

1 7 1

9

1 7 1

9

1 7 1

9

1 8 2

0

1 8 2

0

1 8 2

0

1 2 1

4

1 2 1

4

R e m

R e m

R e m

R e m

R e m

R e m

R e m

R e m

R e m

2 . 0 0

1 . 5 0

7 . 5 1 0

. 0

7 . 0 9 . 0

1 . 0 2 . 5

1 . 0 2 . 5

1 . 0 2 . 5

1 . 0 0

0 . 6 0

2 . 0 3 . 0

2 . 0 3 . 0

2 . 0 3 . 0

8 . 0 1 1

. 0

7 . 0 9 . 0

4 . 0 6 . 0

4 . 0 6 . 0

1 1 1 4

1 1 1 4

1 1 1 4

1 . 0

0

0 . 6

0

0 . 0 4 5

0 . 0 6 0

0 . 0 3 0

0 . 0 3 0

0 . 0 3 0

0 . 0 2 0

1 . 0 0

0 . 5 0

1 . 0 0

0 . 0 8 0

0 . 3 0 0 . 6

5

0 . 3 0 0 . 6

5

0 . 6 5 1 . 0

0

0 . 0 8 0

0 . 5 0

0 . 0 4 5

0 . 0 3 0

0 . 0 3 0

0 . 0 3 0

0 . 0 2 0

C u

C u

C u

0 . 7 5

0 . 7 5

0 . 7 5

N o t e s :

( 1 ) S i n g

l e v a

l u e s s h o w n a r e m a x i m u m p e r c e n

t a g e s .

R e m = r e m a i n d e r ,

( 2 ) S A E / A S T M U n i

f i e d N u m

b e r i n g

S y s t e m

f o r M e t a l s a n

d A l l o y s .

( 3 ) C a r

b o n s t e e

l s n o m

i n a l

l y c o n t a

i n < 1 . 5 M n ,

< 0 . 3 5 S i

, a n d

< 0 . 9 0 C

.

( 4 ) A l l o y s t e e

l s n o m

i n a l

l y c o n t a i n

h i g h e r

M n ,

S i , o

r C r c o n

t e n t

t h a n c a r b o n s t e e

l s .

( 5 ) S t a i n l e s s s t e e

l s n o m

i n a l

l y c o n t a i n

> 1 0 C r .

( 6 ) 0 . 5 0 m a x

i m u m

f o r a r c s p r a y i n g .



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AWS C2.25/C2.25M:2002

4

T a b l e

2

C 2 . 2 5

C l a s s

i f i c a

t i o n

U N S

N o .

( 2 )

C o m m o n

N a m e

C o m p o s i

t i o n ,

W e i g h

t P e r c e n t

( 1 )

A l

C

C r

C u

F e

M n

M o

N i

P

P b

S

S b

S i

S n

T i

Z

n

O t h e r s

A m o u n t

W - A

l - 1 1 0 0

A 9 1 1 0 0

1 1 0 0 A l u m

i n u m

9 9 . 0

0 m

i n

0 . 0 5

0 . 2 0

0 . 9 5

( F e +

S i )

0 . 0 5

0 . 9 5

( F e +

S i )

0 . 1

0

( 4 ) , ( 6 )

( 4 ) , ( 6 )

W - A

l - 1 3 5 0

A 9 1 3 5 0

1 3 5 0 A l u m

i n u m

9 9 . 5

0 m

i n

0 . 0 1

0 . 0 5

0 . 4 0

0 . 0 1

0 . 1 0

0 . 0 2

( V + T i )

G a B

( 4 ) , ( 7 )

0 . 0 3 ( 6 )

0 . 0 5 ( 7 )

W - A

l - 4 0 4 3

A 9 4 0 4 3

4 0 4 3 S i l i c o n

A l u m

i n u m

R e m

0 . 3 0

0 . 8

0 . 0 5

4 . 5

6 . 0

0 . 2 0

0 . 1

0

M g

( 4 ) , ( 6 )

0 . 0 5 ( 6 )

W - A

l - 4 0 4 7

A 9 4 0 4 7

4 0 4 7 S i l i c o n

A l u m

i n u m

R e m

0 . 3 0

0 . 8

0 . 1 5

1 1 . 0

1 3 . 0

0 . 2

0

M g

( 4 ) , ( 6 )

0 . 1 0 ( 6 )

W - A

l - 5 3 5 6

A 9 5 3 5 6

5 3 5 6 M g

A l u m

i n u m

R e m

0 . 0 5

0 . 2 0

0 . 1 0

0 . 4 0

0 . 0 5

0 . 2 0

0 . 2 5

0 . 0 6

0 . 2 0

0 . 1

0

M g

( 4 ) , ( 6 )

4 . 5 5 . 5 ( 6 )

W - A

l - A l 2 O

3

A 7 1 0 0 1

A l M M C ( 3 )

8 8 m

i n

A l 2 O

3 ( 4 )

8 1 2

W - C

d

L 0 1 9 5 0

C a d m i u m

C d

9 9 . 8

m i n

W - C u

C 1 1 0 8 0

C o p p e r

9 9 . 8

m i n

W - C u S n

C 5 1 8 0 0

P h o s p h o r b r o n z e

9 3 . 5

9 6 . 5

0 . 0 3

0 . 3 5

3 . 5 6 . 0

0 . 3

0

W - C u A

l

C 6 1 8 0 0

A l u m

i n u m

b r o n z e

9 1 0

8 8 . 0

m i n

0 . 7 1 . 3

W - C u Z n -

1

C 2 2 0 0 0

C o m m e r c

i a l b r a s s

8 9 9

1

0 . 0 5

0 . 0 5

R e m

W - C u Z n -

2

C 2 6 8 0 0

M a c

h i n a b l e

b r a s s

6 4 6

9

0 . 0 6

0 . 1 5

R e m

W - C u Z n -

3

C 4 7 0 0 0

N a v a l b r a s s

5 7 6

1

1 . 0

0 . 5

0 . 3

0 . 5 1 . 0

R e m

W - C u Z n A g

C 5 6 0 0 0

S i l v e r a l

l o y

3 7 3

9

3 0 3

4

A g

2 9 3

1

W - M o

R 0 3 6 1 5

M o l y b d e n u m

9 9 . 0

m i n

W - N

i - 3

N 0 2 2 0 2

N i c k e l

0 . 1 5

0 . 2 5

0 . 6

0 . 3 5

9 7 m

i n

0 . 0 4

0 . 5

W - N

i - 2

N 0 2 2 0 0

N i c k e l

9 9 . 0

m i n

W - N

i A l - 1

N 0 1 0 0 1

N i c k e l A l u m

i n u m

4 6

R e m

W - N

i A l - 2

N 0 1 0 0 2

N i c k e l A l u m

i n u m

( 5 ) 1 7 2

7

R e m

T o t a l

1 . 0

W - N

i A l F e

1 4 2

6

2 . 5 5 . 5

1 7 2 3

R e m

Z r O 2

T o t a l

1 . 5 4 . 5

2 . 0

W - N

i C r F e -

1

N 0 6 0 7 6

N i c k e l - C h r o m

i u m ,

l o w

i r o n

0 . 4

0 . 1 5

1 9 2

1

0 . 5

3 . 0

1 . 0

7 5 m

i n

0 . 0 2

0 . 3

T i

0 . 5

W - N

i C r F e -

2

N 0 6 0 7 8


i u m ,

h i g h

i r o n

0 . 1 0

1 4 1

7

0 . 5

6 1 0

1 . 0

7 2 m

i n

0 . 0 2

0 . 5

W - N

i C r F e -

3

N 0 6 0 0 4


i u m -

I r o n

0 . 2 5

1 4 1

8

R e m

1 . 0

5 7 m

i n

0 . 0 1

1 . 5

T a b l e

2

C h e m

i c a l

C o m p o s i

t i o n

R e q u

i r e m e n

t s f o r

S o

l i d N o n

f e r r o u s

T h e r m a l

S p r a y

W i r e s

( C o n

t i n u e

d )



--` `

,` ` -` -`

, ,`

, ,`

,`

, ,` ---


14/27

AWS C2.25/C2.25M:2002

5

W - N

i C r M o

N 0 6 0 2 1


i u m -

M o l y b d e n u m

2 1 2

3

1 3

9 1 1

R e m

T o t a l

3 4

W - N

i C r T

i

N 0 6 0 7 0


i u m -

T i t a n i u m

4 4 4

6

R e m

3 4

W - N

i C u -

1

N 0 4 4 0 5

N i c k e l C o p p e r

0 . 5 0

0 . 3 0

R e m

2 . 5

2 . 0

6 3 7

0

( N i + C o )

0 . 0 4

0 . 5

W - N

i C u -

2

N 0 4 4 0 6

N i c k e l C o p p e r

0 . 1 0

0 . 2 5

2 6 2

8

2

1 . 5

R e m

0 . 2 5

W - P

b

L 5 0 0 4 5

L e a d

9 9 . 5 m i n

W - P

b S n

L 5 3 1 0 5

A n t

i m o n y -

L e a d

R e m

5 7

W - P

b S b S n

L 5 3 4 6 5

B a b

b i t t , l e a d

b a s e

d

0 . 7 5

7 6 8

0

1 2 1

3

8 1 0

W - S n

L 1 3 0 1 0

T i n

9 9 . 7

m i n

W - S n C u S

b

L 5 3 1 0 5

B a b

b i t t , l e a d

f r e e

4 5

4 5

9 0 9

1

W - S n S

b C u -

1 L 1 3 8 9 0

B a b

b i t t , t i n b a s e

d

3 . 5 4 . 5

0 . 3 5

7 . 0 8 . 0

R e m

W - S n S

b C u -

2 L 1 3 8 9 2

B a b

b i t t

3 5

0 . 5 0

6 9

R e m

W - S n S

b C u -

3 L 1 3 8 9 3

B a b

b i t t

2 4

6 8

R e m

W - S n Z n -

1

L 1 3 2 0 1

8 0 / 2 0 T i n - Z

i n c

R e m

1 9 2

1

W - S n Z n -

2

L 1 3 2 0 2

7 0 / 3 0 T i n - Z

i n c

0 . 0 1 0

R e m

2 6 3

4

W - T

i

R 5 0 1 2 0

T i t a n i u m

9 9 . 8

m i n

W - Z n -

1

Z 1 3 0 0 5

9 9 . 9

9 Z i n c

0 . 0 0 2

0 . 0 0 5

0 . 0 0 3

0 0 . 0 0

3

0 . 0 0 1

9 9 . 9 9

m i n

C d

0 . 0 0 3

W - Z n -

2

Z 1 5 0 0 5

9 9 . 9

Z i n c

0 . 0 1

0 . 0 2 0

0 . 0 2 0

0 0 . 0 3

0

9 9 . 9

m i n

C d

0 . 0 2 0

W - Z n A

l - 1

Z 3 0 4 0 2

9 8 / 2 Z i n c -

A l u m

i n u m

1 . 5 2 . 5

R e m

T o t a l

0 . 1 0 0

W - Z n A

l - 2

Z 3 0 7 0 0

8 5 / 1 5 Z i n c -

A l u m

i n u m

1 4 . 0

1 6 . 0

R e m

T o t a l

0 . 0 5 0

N o t e s :

( 1 ) S i n g

l e v a

l u e s a r e m a x

i m u m p e r c e n

t a g e s u n

l e s s a m

i n i m u m

i s s p e c

i f i e d . R

e m =

r e m a i n d e r .

( 2 ) S A E / A S T M U n i

f i e d N u m

b e r i n g

S y s t e m


d A l l o y s .

( 3 ) V o l - % A l u m

i n u m

A s s n .

1 0 6 0 a l

l o y w

i t h a d

d i t i o n o f

8 t o 1 2 v o

l - % A l 2 O

3 p o w d e r , 8 1

0 m

d i a m e t e r .

( 4 ) 0 . 0 0 0 8 p e r c e n

t B e m a x

i m u m .

( 5 ) T h e m a t e r

i a l s w

i l l p r o d u c e a n e x o t

h e r m

i c r e a c

t i o n

d u r i n g s p r a y i n g .

( 6 ) A l l o t

h e r e

l e m e n

t s t y p i c a

l l y a n a l y z e d

f o r t

h e w

i r e :

0 . 0 5 m a x e a c h ; 0 . 1

5 m a x

t o t a l .

( 7 ) A l l o t

h e r e

l e m e n

t s t y p i c a

l l y a n a l y z e d

f o r t

h e w

i r e :

0 . 0 3 m a x e a c h ; 0 . 1

0 m a x

t o t a l .

T a b l e 2 ( C o n

t i n u e d

)

C 2 . 2 5

C l a s s

i f i c a

t i o n

U N S

N o .

( 2 )

C o m m o n

N a m e

C o m p o s i

t i o n ,

W e i g h

t P e r c e n t

( 1 )

A l

C

C r

C u

F e

M n

M o

N i

P

P b

S

S b

S i

S n

T i

Z

n

O t h e r s

A m o u n t




15/27

AWS C2.25/C2.25M:2002

6

T a b l e

3

C h e m

i c a l

C o m p o s i

t i o n

R e q u

i r e m e n

t s f o r

C o r e

d C o m p o s i

t e T h e r m a l

S p r a y

W i r e s

C 2 . 2 5

C l a s s

i f i c a

t i o n

U N S

N u m

b e r ( 2

)

C o m m o n

N a m e

C o m p o s i t i o n ,

W e i g h

t P e r c e n t

( 1 )

A l

B

C

C r

C u

F e

M n

M o

N i

S i

Y

O t h e r s

A m o u n t

C W - C o C r W

C W - C o M o C r

W 7 3 1 3 6

W 7 3 1 3 8

C o b a l t H a r

d f a c

i n g

C o b a l t H a r

d f a c

i n g

0 . 9 0 1 . 3

0

0 . 0 8

2 7 3

1

1 7 1

9

3

1 . 0

1 . 0

2 7 3

0

3

1 . 5

3 . 2 3 . 8

C o W C

o

R e m

4 . 0 6 . 0

R e m

C W - C r F e B

W 7 4 6 3 0

C h r o m

i u m - I r o n -

B o r o n

7 9

R e m

3 4 3

6

3 . 5 4 . 5

2 . 5 3 . 5

C W - C u A

l F e

C W - C u S n S

i

W 6 1 6 2 6

W 6 0 6 5 8

A l u m

i n u m

B r o n z e

S i l i c o n

B r o n z e

1 3 1

6

0 . 5 1 . 5

R e m

R e m

3 5

1 . 5 2 . 5

S n

5 . 0 6 . 0

C W - F e C r -

1

C W - F e C r -

2

C W - F e C r -

3

C W - F e C r -

4

C W - F e C r C - 1

C W - F e C r C - 2

C W - F e C r N

i B

W 4 1 0 3 6

W 4 1 0 3 9

W 4 2 0 4 0

W 4 3 0 7 0

W 7 4 5 3 2

W 7 4 5 3 5

W 8 9 6 4 0

4 1 0

N i c k e l M o l y b

d e n u m

S S

4 1 0

N i c k e l S S

4 2 0

S S

4 3 0

S S

H a r d

f a c i n g

A l l o y

H a r d

f a c i n g

A l l o y

I r o n -

C h r o m

i u m - N

i c k e l - B o r o n

2 . 5 3

. 5

0 . 0 6

0 . 0 6

0 . 2 0 0 . 4

0

0 . 6 0 0 . 8

0

4 . 0 5 . 0

1 . 5 2 . 0

1 1 1

3

1 2 1

4

1 2 1

4

1 6 1

8

1 8 2

1

2 4 2

8

3 0 3

2

2 . 5 3 . 5

R e m

R e m

R e m

R e m

R e m

R e m

R e m

1 . 0

1 . 0

1 . 0

1 . 0

2 . 5

2 . 5

0 . 4 0 0 . 7

0

0 . 7 5

2 . 0

2 . 0

3 . 5 4 . 5

4 . 0 5 . 0

3 . 0 4 . 0

2 . 0 4 . 0

2 9 3

1

1 . 0 1 .

0 1 . 0

2 . 5

2 . 5

C W - F e M n A

l

W 7 9 8 4 0

I r o n -

M a n g a n e s e - A

l u m

i n u m

4 5

R e m

6 8

1 2

C W - F e V

W C

C W - F e W

C

W 7 7 5 4 0

W 7 7 6 4 0

T u n g s t e n

V a n a d

i u m

C a r

b i d e

T u n g s t e n

C a r

b i d e

1 . 0

3 . 5 4 . 5

2 . 0 3 . 0

R e m

R e m

1 . 5

1 . 0

1 . 0

1 . 0

2 . 0

W V W

5 . 0 7 . 0

1 5 1

7

5 6 6

0

C W - F e C r B

C W - F e C r N

i B

C W - F e C r N

i M o B

W 4 6 4 4 0

W 4 6 5 4 0

W 4 6 6 4 0

M e t a m o r p h

i c A l l o y

M e t a m o r p h

i c A l l o y

M e t a m o r p h

i c A l l o y

4 . 3 2 . 5 3 . 0

0 . 2 0

0 . 2 0

0 . 2 0

3 2 2 5 2 5

2 . 2

2 . 7

R e m

R e m

R e m

1 . 8

1 . 2 5

1 . 5

4 . 2

3 . 5

1 0 8 . 0

2 . 1

1 . 5

2 . 2

C W - N

i C r A

l

C W - N

i A l M o

C W - N

i C r A

l Y

C W - N

i C r F e

C W - N

i C r M o

C W - N

i C r S

i B

C W - N

i F e A

l

W 8 9 3 4 1

W 8 9 3 4 2

W 8 9 3 4 3

W 8 7 7 4 0

W 8 6 1 4 2

W 8 9 7 4 0

W 8 9 2 4 0

N i c k e l - C h r o m e -

A l u m

i n u m

N i c k e l - A l u m

i n u m - M o l y b

d e n u m


i u m - A

l u m

i n u m -

Y t t r i u m


i u m - I r o n

A l l o y

6 2 5

S e l f - F l u x

i n g

A l l o y

6 7

5 . 0 6 . 0

9 1 1

1 4 1

6

2 . 5 3

. 0

0 . 1 0

0 . 5 1 . 0

1 8 2

0

2 1 2

3

1 7 1

9

2 0 2

3

1 2 1

8 3 5

1 8 2

0 5

1 . 0 3 . 5

1 7 2

3

0 . 5

4 . 5 5 . 5

2 . 5 3 . 5

8 . 0 1 0

. 0

R e m

R e m

R e m

R e m

R e m

R e m

R e m

3 . 5 5 . 5

0 . 5 1 . 5

T o t a l

O t h e r s

T i T a N b

6 0 . 5 1 . 5

4 . 5 5 . 5

3 . 2 4 . 2

N o t e s :

( 1 ) S i n g

l e v a

l u e s s h o w n a r e m a x i m u m p e r c e n

t a g e s .

R e m = r e m a i n d e r .

( 2 ) S A E / A S T M U n i

f i e d N u m

b e r i n g

S y s t e m


d A l l o y s .




16/27

AWS C2.25/C2.25M:2002

7

T a b l e

4

C h e m

i c a l

C o m p o s i

t i o n

R e q u

i r e m e n

t s f o r

T h e r m a l

S p r a y

C e r a m

i c R o

d s

C 2 . 2 5

D e s

i g n a

t i o n

C o m m o n

N a m e

C o m p o s i

t i o n ,

W e i g h

t P e r c e n t

( 1 )

A l 2 O

3

C a O

C r 2 O 3

S i O

2

F e 2 O 3

T i O

2

N a O 2

Z r O

2

M g O

Y 2 O 3

O t h e r s

A m o u n t

C R - C r 2

O 3 -

1

C R - C r 2

O 3 -

2

C R - C r 2

O 3 -

3

C h r o m e

O x i d e

C h r o m e

O x i d e

C h r o m e

O x i d e

2 . 0 2 . 4

2 . 8 3 . 6

3 . 3 4 . 1

0 . 6 0 . 7

1 . 1 1 . 5

0 . 1 0 . 2

R e m

R e m

R e m

1 1 1

3

7 . 9 8 . 9

5 . 2 6 . 8

0 . 3 0 . 7

0 . 6 0 . 9

0 . 2 0 . 3

0 . 1 0 . 2

0 . 2 0 . 4

0 . 1 0 . 2

3 . 5 3 . 7

2 . 7 3 . 1

0 . 1 0 . 2

C R - A

l 2 O

3 - 1

C R - A

l 2 O

3 - 2

C R - A

l 2 O

3 - 3

C R - A

l 2 O

3 - 4

C R - A

l 2 O

3 - 5

C R - A

l 2 O

3 - 6

C R - A

l 2 O

3 - 7

C R - A

l 2 O

3 - 8

A l u m

i n u m

O x i d e

A l u m

i n u m

O x i d e

A l u m

i n u m

O x i d e

A l u m

i n u m

O x i d e

A l u m

i n a

T i t a n i a

A l u m

i n a

T i t a n i a

A l u m

i n a

T i t a n i a

S p i n e l

R e m

R e m

R e m

R e m

R e m

R e m

R e m

R e m

0 . 1 0 . 2

0 . 0 3

0 . 1 0 . 2

0 . 1 0

0 . 1 0 . 3

0 . 1 0 . 3

0 . 1 0 . 3

0 . 3 0 . 4

0 . 7 0 . 9

0 . 0 4

0 . 1 0

0 . 7 1 . 1

0 . 6 0 . 8

0 . 4 0 . 6

0 . 4 0 . 6

1 . 6 1 . 8

0 . 0 3 0 . 0

7

0 . 0 9

0 . 0 2

0 . 0 3

0 . 4 0 . 6

0 . 2 0 . 4

0 . 2 0 . 4

0 . 1 0 . 3

0 . 0 1

0 . 0 3

0 . 0 3

0 . 0 3

3 . 0 3 . 2

1 2 1

6

3 9 4

3

0 . 0 4

0 . 2 0 . 4

0 . 0 6

0 . 0 3 0 .

0 4

0 . 1 0 . 3

0 . 1 0 . 3

0 . 1 0

0 . 1 0

0 . 1 0 . 2

0 . 0 1

0 . 3 0 . 4

0 . 0 1

0 . 0 1

0 . 0 1

0 . 4 0 . 5

0 . 2 0 . 4

0 . 2 0 . 4

3 2 3

3

C R - Z r O 2 -

1

C R - Z r O 2 -

2

C R - Z r O 2 -

3

C R - Z r O 2 -

4

C R - Z r O 2 -

5

Z i r c o n

i u m

O x i d e

Z i r c o n

i u m

O x i d e

Z i r c o n

i u m

O x i d e

M a g n e s i u m

Z i r c o n a

t e

Z i r c o n

i u m

S i l i c a t e

0 . 6 0 . 8

2 . 0 2 . 6

0 . 0 9 0 . 1

3

0 . 8 1 . 1

3 . 3 3 . 7

3 . 8 4 . 4

0 . 0 3

0 . 2 0 . 3

0 . 8 1 . 0

0 . 2 0 . 4

2 . 7 3 . 2

0 . 3 0 . 5

0 . 3 0 . 4

3 7 4

2

0 . 4 0

0 . 0 8

0 . 0 4

0 . 0 8

0 . 0 9

0 . 4 0 . 5

0 . 3 0 . 5

0 . 1 0 . 2

0 . 2 0 . 3

0 . 1 0 . 2

0 . 0 2

0 . 0 2

0 . 0 4 0 .

0 7

R e m

R e m

R e m

R e m

R e m

0 . 0 6

0 . 0 7

0 . 0 2

2 1 2

2

0 . 3 0 . 5

7 . 6 8 . 3

H f

H f

H f

H f

H f

0 . 0 2

0 . 0 2

0 . 0 2

0 . 0 2

0 . 0 2

N o t e s :

( 1 ) S i n g

l e v a

l u e s a r e m a x

i m u m p e r c e n

t a g e s .

R e m = r e m a i n d e r .




17/27

AWS C2.25/C2.25M:2002

8

analysis, retest need be only for those specific elementsthat failed to meet the test requirement. If the results of one or both retests fail to meet the requirement, the mate-rial under test shall be considered as not meeting the re-quirements of this specification for that classification.

6.2.2 In the event that, during preparation or aftercompletion of any test, it is clearly determined that pre-scribed or proper procedures were not followed in pre-paring the test specimens or in conducting the test, thetest shall be considered invalid, without regard towhether the test was actually completed, or whether testresults met, or failed to meet, the requirement. That testshall be repeated, following proper prescribed proce-dures. In this case, the requirement for doubling the num-ber of test specimens does not apply.

7. Method of Manufacture

Thermal-spray solid and composite wires and ceramicrods classified according to this specification may bemanufactured by any method, which meets the require-ments of this specification.

8. Standard SizesStandard sizes for thermal-spray wires and ceramic

rods in the different package forms (coils with support,

coils without support, spools, and drums, and straightlengths for ceramic rods see Section 10) are shown inTables 5 and 6. Note: When ordering thermal-spray wire

for flame thermal spraying, the wire maximum diameter and tolerance required by the spray gun manufacturer,i.e., the spray gun nozzle diameter, should be specified.

9. Finish and UniformityThe finish and uniformity of thermal-spray wires shall

meet the following requirements:(1) All thermal-spray wires shall have a smooth finish

that is free from slivers, depressions, scratches, scale,laps, and foreign matter that would adversely affect wirefeedability or the properties of the thermal-spray wire.

(2) Each continuous length of thermal-spray wireshall be from a single heat or lot of material. Welds,when present, shall be made so as not to interfere withthe uniform, uninterrupted feeding of the thermal-spraywire in automatic or semiautomatic equipment.

(3) Cored composite wires shall have the core ingre-dients evenly distributed throughout their length so as notto adversely affect the performance of the thermal-spraywire, or the deposited thermal-spray coating properties.

(4) Carbon steel thermal-spray wires may be pro-tected with a flash coat of copper when necessary to pre-vent corrosion during storage.

W for solid alloy and solid composite wiresPrefix Letter(s) CW for cored composite wires

CR for ceramic rods

Dash to separate prefix letter(s) from the chemical composition designation

Major chemical elements in percentage order of the solid and cored wires, ceramic rods, or the AluminumAssociation alloy designation

Dash to separate similar chemical compositions from the suffix number

Suffix number to differentiate similar chemical compositions in solid wires, cored wires, and ceramicrods

Major chemical composition of the ceramic material in a metal matrix composite

XX - xxxx - N - yyyy

Examples:A. W-FeC-2 The second ( 2) carbon steel ( FeC ) solid wire.B. W-Al-Al 2O3 A solid ceramic composite ( Al2O3) in a metal matrix ( Al) wire.C. CW-CrFeB A cored composite chrome-iron-boron ( CrFeB ) composite wire.D. CR-ZrO 2-3 The third ( 3) zirconium oxide ( ZrO 2) ceramic rod.

Figure 1Thermal Spray Feedstock Classification System Format



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9

(5) Subject to agreement between the purchaser andthe supplier, a very small amount of specified lubricantthat will not degrade the deposited coating may be ap-plied to the thermal-spray wire to permit smooth and low-friction feeding through the thermal-spray equipment.

10. Standard Packaging Forms

Standard packaging forms are (a) coils with and with-out support, drums, and spools for solid and compositewires and (b) straight lengths for ceramic rods. Standardpackage dimensions and weights for the thermal-spraywires are given in Table 7. Dimensions for standardspools are given in Figures 2 and 3. Package forms, sizes,

and weights other than these shall be as agreed uponbetween purchaser and supplier.

10.1 Coils with Support

10.1.1 The liners in coils with support shall be de-

signed and constructed to prevent distortion of the coilduring normal handling and use. They shall be clean anddry to maintain the cleanliness of the thermal-spray wire.

10.2 Spools

10.2.1 Spools shall be designed and constructed toprevent distortion of the spool and thermal-spray wireduring normal handling and use. They shall be clean anddry to maintain the cleanliness of the thermal-spray wire.

Table 5Standard Sizes for Thermal Spray Wires

Standard Package Form

Wire Diameter Tolerance

C2.25 C2.25M C2.25 C2.25M

in. mm in. mmCoils With andWithout Support

0.0450.0470.0550.0590.0630.078

1.21.4

(1) 1.5 (1)1.62.0

+0.001+0.001+0.001+0.001+0.001+0.001

0.0020.0020.0020.0030.0030.003

+0.03+0.03+0.03+0.03+0.03

0.060.060.080.080.10

Drums 0.0910.094

(1) 2.3 (1)2.4

+0.001+0.001

0.0040.004

+0.03+0.03

0.100.11

Spools 0.1250.1560.1880.196

3.24.0

(1) 4.8 (1)5.0

+0.002+0.002+0.002+0.002

0.0040.0040.0040.004

+0.03+0.03+0.03+0.03

0.130.130.130.13

Note:(1) Metric sizes not shown in ISO 544.

Table 6Standard Sizes for Thermal Spray Ceramic Rods

Standard Package Form

Rod Diameter Tolerance

C2.25 C2.25M C2.25 C2.25M

in. mm in. mm

100 pieces100 pieces50 pieces

0.1830.2440.307

4.66.27.8

+0.005+0.005+0.005

000

+0.13+0.13+0.13

000



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The use of insulated spools shall be agreed upon betweenpurchaser and supplier.

10.3 Ceramic Rods

10.3.1 Ceramic rods shall be packaged in impact re-sistant tubular containers to prevent breakage duringshipment.

11. Winding Requirements11.1 Winding

11.1.1 Thermal-spray wire on spools and in coils (in-cluding reels and drums) shall be wound so that kinks,waves, sharp bends, overlapping, or wedging are not en-countered, leaving the thermal-spray wire free to unwindwithout restriction. The outside end of the thermal-spraywire (the end with which thermal spraying is to begin)shall be identified so it can be located readily and shallbe fastened to avoid unwinding. The outermost layer onspools shall be at least 1/8 in [3 mm] from the rim of theflanges of the spool.

11.1.2 Coils without support shall be wound with aleft-hand configuration so that when the coil is laid hori-

zontal with the beginning end tag up, the coil will un-wind in a counterclockwise direction.

11.2 Cast and Helix

11.2.1 The cast and helix of thermal-spray wires incoils, spools, and drums shall be such that the thermal-spray wire will feed in an uninterrupted manner in auto-matic and semiautomatic equipment.

11.2.2 The cast and helix of thermal-spray wire on12 in. [300 mm] spools shall be such that a specimen

long enough to produce a single loop, when cut from thespool and unrestrained on a flat surface will:

(1) Form a circle not less than 15 in. [380 mm] normore than 50 in. [1300 mm] diameter, and

(2) Rise above the flat surface no more that 1 in.[25 mm] at any location.

11.2.3 Soft alloy wires such as aluminum, copper,lead, and zinc, are exempt from the requirement.

Table 7Standard Packaging Dimensions and Weights for Thermal Spray Wires (1)

Type of Package

Package Size Net Weight (2)

C2.25 Dimension C2.25M C2.25 C2.25M

in. (diameter) mm lb kg

Coils Without Support (3) (3)

Coils With Support 1212 1/812 1/8

InsideInsideInside

300300 3300 3

25, 30, 50, and 6025 and 30

50, 60, and 65

10, 15, 20, and 2510 and 15

20, 25, and 30

Drums .015.52023

OutsideOutsideOutside

400500600 300 and 600

(3)(3)

140 and 270

Spools 1214222430

OutsideOutsideOutsideOutsideOutside

305355560610760

154550 and 60

250300

600, 750, and 1000

102020 and 30

110140

270, 340, and 450

Notes:(1) Sizes and net weights other than those listed may be supplied as agreed between the supplier and purchaser.(2) Tolerance on net weight shall be 10%.(3) As agreed by the supplier and purchaser.



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12. Solid and Composite Wire andCeramic Rod Identification

The product information (14.1) and the precautionaryinformation (14.2) shall be placed on each coil, spool, ordrum of wire and on each package of ceramic rods.

(1) Coils without support shall have a tag containingthis information securely attached to the thermal-spraywire at the inside of the coil.

(2) Coils with support shall have the information se-curely affixed in a prominent location on the support.

Spools shall have this information securely affixed ina prominent location on the outside of at least one flangeof the spool.

Drums shall have the information securely affixed in aprominent location on the side of the drum.

Packages of ceramic rods shall have the informationsecurely affixed in a prominent location on the side of the

package.

13. Packaging

Thermal-spray products shall be suitably packaged toensure against damage during shipment and storageunder normal conditions.

Figure 2 Dimensions of Standard 12- and 14-in. [300- and 350-mm] Spools

12-in. [300-mm] Spools 14-in. [350-mm] Spools

in. mm in. mm

A Spool Diameter, maximum 12 305 14 355

B Spool WidthTolerance4.0

0.06103

3, +04.0

0.6103

3, +0

C Barrel DiameterTolerance2.03

0, +0.0650.5

0, +2.52.03

0, +0.0650.5

0, +2.5

D Distance between AxesTolerance1.75

0.0244.50.5

1.750.02

44.50.5

E Driving Hole DiameterTolerance (Note 2)0.44

0.06, +0.010

0, +10.44

0.06, +0.010

0, +1

Notes:1. Outside diameter of barrel shall be such as to permit feeding of the wire.2. Holes are provided on each flange, but they need not be aligned.

General Notes:

Inside diameter of the barrel shall be such that swelling of the barrel or misalignment of the barrel and flanges will not result in the in-side of the diameter of the barrel being less than the inside diameter of the flanges.

Metric dimensions and tolerances conform to ISO 544 except that A specifies tolerances on the nominal diameter rather than aplus tolerance only, which is shown here as a maximum.



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14. Marking of Packages14.1 Product Information

14.1.1 The following product information, as a mini-mum, shall be legible and visible from the outside of each unit package:

(1) C2.25 specification and classification designation(year of issue may be excluded).

(2) Supplier s name and trade designation.

(3) Size and net weight.(4) Lot, control, or heat number.

14.2 Precautionary Information

14.2.1 The appropriate precautionary information givenin ANSI Z49.1 latest edition (as a minimum) shall beprominently displayed in legible print on all packages, in-cluding individual unit packages within a larger package.

Figure 3 Dimensions of Standard 22-, 24-, and 30-in. [560-, 610-, and 760-mm] Spools

22-in. [560-mm] Spools 24-in. [610-mm] Spools 30-in. [760-mm] Spools

in. mm in. mm in. mmA Spool Diameter, maximum 22 560 24 610 30 760

B Spool Width, maximum 12 305 13.5 345 13.5 345

C Center Hole DiameterTolerance1.31

0, +0.1335.01.5

1.310, +0.13

35.01.5

1.310, +0.13

35.01.5

D Distance, Center to CenterTolerance2.5

0.1363.53

2.50.13

63.51.5

2.50.13

63.53

E Driving Hole DiameterTolerance (Note 1)0.69

0.06, +016.70.7

0.690.06, +0

16.70.7

0.690.06, +0

16.70.7

Note:1. Outside diameter of barrel shall be such as to permit feeding of the wire.

General Notes:

Inside diameter of the barrel shall be such that swelling of the barrel or misalignment of the barrel and flanges will not result in theinside of the diameter of the barrel being less than the inside diameter of the flanges. Two holes are provided on each flange and shall be aligned on both flanges with the center hole.



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For more information, consult 11.8 (Ventilation), AWS

Thermal Spraying: Practice, Theory, and Application,OSHA Safety and Health Standards available from U.S.Government Printing Office, Superintendent of Docu-ments, P.O. Box 371054, Pittsburgh. PA 15250-7954, andthe manufacturer s Material Safety Data Sheet (MSDS).

A number of factors determine the amount of contam-ination to which the workman is exposed when perform-ing blast and thermal spray operations. These include thefollowing:

(1) Volume of space in which the thermal sprayingoperation is to be done

(2) Number of spray and grit blast operators(3) The evolution of hazardous fumes, gases, or dusts

depending on what type of abrasive process is used ormaterial being sprayed

(4) Heat generated by the spraying process(5) Presence of volatile solventsAll of the preceding should be considered in order to

better protect the operators and to supply adequate venti-lation to the spray room.

Local exhaust or general ventilation systems shouldbe provided to control toxic fumes, gases, or dusts, andtheir removal from the work area.

Where thermal spraying operations are incidental togeneral operations, it is good practice to apply local ex-

haust ventilation to the spray areas. This prevents con-tamination of the general work area.Individual respiratory protective devices should be well

maintained. They should not be transferred from one em-ployee to another without being cleaned and disinfected.Refer to ANSI/ASC Z88.2 for cleansing and disinfecting. 4

4. ANSI standards can be obtained from American National Stan-dards Institute, 11 West 42nd Street, New York, NY 10036-8002.

Forced-air respiratory devices require Grade D or bet-

ter air per Compressed Gas Association, CGA No. G-7.1,Commodity Specification for Air .5

Mechanical ventilation or local exhaust ventilation isrequired in spraying and blasting operations that are notperformed in the open or in a properly designed and ven-tilated room. Otherwise, the dust will rapidly fill a largetank, building, or semi-enclosed space.

The ventilation equipment for most field thermalspray and blast operations consists of engine- or motor-or air- (venturi) driven portable exhausters with flexiblepiping or ducts. This removes the dust rapidly and allowsoperators suitable visibility. Systems of this type havedeficiencies, and operators should wear respiratory de-vices approved by the U.S. Bureau of Mines, NIOSH, orother approved authority for the purpose intended. Selec-tion of the respiratory device should follow the guide-lines of ANSI/ASC Z88.2.

When removing dust with portable exhausters, it isnecessary to attach a dust collector to trap the dust andprevent contamination of the surrounding areas.

In shop environments, use wet (water wash), bag, orfilter type collectors for gathering spray dust. Dust col-lectors must be replaced and ventilation ducts kept cleanbefore entrapped dust builds up to create an explosionhazard or seriously reduces the efficiency of the system.

If thermal spraying operations are performed on a ma-chine tool such as a lathe, an exhaust hood should bemounted at the edge of the carriage so that it travels withthe gun. This allows the dust and fumes to be exhaustedinto the dust collector. The gun is aimed so that the

5. CGA documents can be obtained from the Compressed GasAssociation, Inc., 1725 Jefferson Davis Hwy., Suite 1004,Arlington, VA 22202-4102.

Annex AGuide to Ventilation and Personnel

Protection During Thermal Spraying(This Annex is not a part of AWS C2.25/C2.25M:2002, Specification for Thermal Spray Feedstock-Solid and Com-

posite Wires and Ceramic Rods, but is included for information purposes only.)

Nonmandatory Annexes



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sprayed material enters the face area of the hood. The av-erage size of the opening in a lathe hood is about 2 ft 2

[0.2 m 2], and the velocity of the air entering the openingshould be a minimum of 200 ft/min [1 m/sec]. The hoodopening should eliminate turbulence along the sides thatcould force the spray dust into the operator s breathingzone. In some permanent installations, the entire lathe,

rotary table, or machine tool is enclosed except the front,and the velocity of the air entering the enclosure is ap-proximately 300 ft/min [1.5 m/sec]. The top of the hoodcan be hinged, permitting use of a crane for loading orunloading. In automatic and production spraying, the en-tire mechanism is often totally enclosed, and the dust isexhausted into a water wash and collecting system. In-dustrial Ventilation , published by the American Confer-ence of Governmental Industrial Hygienists, should beconsulted.

During dry grinding or lapping operations on sprayedcoatings, precautions should be taken to provide properexhaust equipment. ANSI/ASC Z43.1 , Ventilation Con-trol of Grinding, Polishing, and Buffing Metals , shouldbe consulted.

Spray cabinets used for spraying small and mediumsize parts should be equipped with exhaust ventilation,with an air velocity of 200 to 400 ft/min [1 to 2 m/sec]entering the hood. The spray equipment should be oper-ated within the face area of the hood and directed into it.Again, the design of the cabinet should be such thatturbulent eddy currents are eliminated. When sprayingtoxic materials, minimum enclosure face velocity of 400 ft/min [2 m/sec] should be used. Industrial Ventila-tion, published by the American Conference of Govern-

mental Industrial Hygienists, should be consulted.6

Blasting rooms should be designed to be well lightedand adequately ventilated. Ventilation should providedown draft and longitudinal airflow with a velocity of 80 to 100 ft/min [0.2 to 0.5 m/sec]. The blasting roomshould be equipped with a dust-collecting system. This is

6. ACGIH documents can be obtained from the AmericanConference of Governmental Industrial Hygienists, 1330Kemper Meadow Drive, Suite 600, Cincinnati, OH 95240-1634.

usually required by local ordinances. Further, local, state,and federal regulations should be investigated before ex-hausting directly into the atmosphere. The blasting roommay also occasionally be used for spraying. This is notgood practice and should be avoided whenever possible.Spray dust will quickly clog most cloth dust collectorsused in the blasting rooms. Moreover, when spraying in a

blasting room, the dust-collector system will require morefrequent maintenance to prevent fire or explosion due toaccumulation of metallic dust. All personnel in the blast-ing room should be provided with respiratory protection.

When ventilating confined spaces, all air replacingthat withdrawn should be clean and respirable. If porta-ble gasoline or diesel engine-driven ventilators or com-pressors are used, they should be located so that engineexhaust gases cannot be drawn into the ventilating sys-tem. This precaution will also prevent exhaust gasesfrom entering the intake of the compressor. This is par-ticularly critical if the air is to be used for respirators.

If dust collectors are used, closed-type collectorsshould be provided with blowout holes or relief panels.Blowout panels should also be provided in ventilationpiping.

All fans, pipes, dust arrestors, and motors should begrounded. Grounds should not be attached to pipes thatcarry fuel gas or oxygen. Ventilating fans should be keptrunning when cleaning out booths, pipes, etc. This pre-vents the accumulation of dust or fumes in the system.Aluminum and magnesium dusts present an explosivehazard which requires special attention. Adequate wetcollector systems should be used with either of thesemetals. Care should be exercised, since these metallic

dusts may generate hydrogen gas in water. These systemsshould be designed to prevent hydrogen accumulation.Frequent clean out operations should be performed to re-duce residues.

When spraying on unusually large objects or in largeconfined spaces, such as encountered in boilers andtanks, it is imperative that fresh-air helmets and protec-tive clothing be worn (see Figure A1).

No welding or cutting should be done in the repair of any ventilation or dust-collecting equipment, unless theequipment has been thoroughly cleaned.



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General Note: Notice extensive safety equipment.

Figure A1 Arc Spraying 85/15 Zn/Al on the Interior of a7-ft Diameter Steel Water Pipe Over the Missouri River, 1998

Courtesy of the Montana Department of Natural Resources and Conservation.Thermal Spray Applicator Courtesy of Interstate Coatings, Inc., Seattle, WA.



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