Material Product Data Sheet

Iron Chromium (Cr ≤ 20 %) Stainless Steel Thermal Spray Wires

Thermal Spray Solid Wire Products: Quick Facts

Metcoloy 1, Metcoloy 2, Metcoloy 4, Metcoloy 5
Classification Wire, Fe-based (FeCr steel)
Thermal Spray Cored Wire Products: Metco 8238
Chemical formula Various

1 Introduction Manufacture Drawn or powder filled

Metcoloy™ wires are chromium steel alloys that contain other Purpose Corrosion and wear resistance
alloying elements like nickel, manganese and molybdenum, Process Electric Arc Spray or
etc., that enhance their excellent corrosion and wear resis- Combustion Wire Spray
tance. Wires with additional molybdenum content offer good
resistance in hot and cold sulfuric acid, hydrochloric acid,
vinegar and sulfur dioxide vapor. These wires are exclusively
manufactured for the electric arc wire and combustion wire
thermal spray processes.

Metcoloy wires are most suitable for salvage and restoration.

They are successfully used on machine elements such as
journal surfaces of all kinds, cylinder liners, pistons, valve
stems, pump plungers, impellers, hydraulic rams, valve
plugs, printing and paper rolls, etc.

Metco™ 8238 is a cored wire that contains an alloy filler ma-

terial to provide special properties. Metco 8238 produces
coatings with high adhesion to the base metal, low oxide
content and good protection to friction and erosion. The
coatings also offer high thermal shock resistance up to
600 °C (1000 °F).

1.1 Typical Uses and Applications

n Corrosion and wear resistant coatings for salvage and
restoration
n Machine parts in low concentrated organic acids includ-
ing pump sleeves, Pump impellers, shafts, valves and
printing rollers
n Typical industrial applications where coatings of these
wires are used include agricultural machinery, paper and
printing, textile manufacturing, power generation, cement
industry and paper mill components

DSM-0369.1 – FeCr (Cr ≤ 20%) Stainless Steel Thermal Spray Wires

© 2022 Oerlikon Metco 1
2 Material Information

2.1 Chemical Composition

Product Nominal Composition Weight Percent (nominal)

Fe Cr Ni Mn Mo C Ti Si Other
(max)
Metcoloy 1 Fe 18Cr 8Ni 2Mn 0.75Si 0.08C Bal. 18.0 8.0 2.0 – 0.08 – 0.75 0.06
Metcoloy 2 Fe 13Cr 0.5Mn 0.5Ni 0.35C 0.25Si Bal. 13.0 0.5 0.5 – 0.35 – 0.25 0.54
Metcoloy 4 Fe 17Cr 12Ni 2.5Mo 2Mn 1Si 0.08C Bal. 17.0 12.0 2.0 2.5 0.08 – 1.0 NR
Metcoloy 5 Fe 18Cr 8.5Mn 5Ni 1Si 0.15C Bal. 18.0 5.0 8.5 – 0.15 – 1.0 NR
Metco 8238 Fe 17Cr 3Ti 1.5Mn 1.3Si Bal. 17.0 – 1.5 – – 3.0 1.3 NR

NR = not reported

2.2 Manufacturing Method, Available Wire Sizes and Recommended Spray Processes

Product Manufacturing Available Wire Diameters

Method 1.6 mm 2 mm 2.3 mm 3.2 mm 4.8 mm
(14 ga) (0.08 in) (11 ga) (1/8 in) (3/16 in)
Metcoloy 1
Metcoloy 2
Metcoloy 4
Metcoloy 5
Metco 8238

Solid wire Cored wire Electric Arc Wire Spray Combustion Wire Spray

2.3 Key Selection Criteria and is often chosen for resurfacing rolls for paper
n Metcoloy 1 is a good choice for applications where high production.
machinability and corrosion protection is required. As this n Metcoloy 5 is recommended for applications where high
is a high shrink material, it is recommended for use in corrosion resistance and relatively low wear protection are
grooves greater than 0.8 mm (0.03 in). required. Coatings of Metcoloy 5 exhibit low shrink and
n Metcoloy 2 is recommended for applications that require are recommend for internal diameters, particularly where
a hard coating with good wear resistance and corrosion thick coatings are needed. Using the combustion wire
protection. It is a low shrink material. It is the best choice spray process, Metcoloy 5 coatings can be sprayed
for coating curved surfaces such as small diameter thicker than Metcoloy 1 coatings, but not as thick as
shafts. Using the combustion wire spray process, Metcoloy 2 coatings. Metcoloy 5 is good for general ma-
Metcoloy 2 can be sprayed very thick, greater than chine element work including hydraulic rams, rolls and for
13 mm (0.5 in), which provides a considerable wear re- applications in the food industry.
serve for use in applications such as hydroelectric plants. n Metco 8238 is recommended for applications requiring
n Metcoloy 4 can be used in applications that require resis- good protection against friction, erosion and thermal
tance or organic and non-oxidizing organic acids at high shock protection at temperatures up to 600 °C (1000 °F).
temperatures. It can also be used in marine environments

DSM-0369.1 – FeCr (Cr ≤ 20%) Stainless Steel Thermal Spray Wires

© 2022 Oerlikon Metco 2
2.4 Related Products n For low temperature applications requiring erosion or cav-
n Metcoloy 33 is a nickel-based steel wire that can be used itation resistance, Diamalloy 1003 is premium grade nick-
when high heat resistance is required. el-chromium stainless steel thermal spray powder applied
n Metco 8295 is a iron-based wire that can be used when using the HVOF spray process.
coatings harder than Metcoloy 2 are required. n Metco 41C is a thermal spray powder that is similar in
n Metco 42C is a stainless steel powder that can be ap- chemistry and use to Diamalloy 1003, but sized for appli-
plied using the combustion powder Thermospray™ or at- cation by atmospheric plasma spray or combustion pow-
mospheric plasma spray processes. This materials is der Thermospray™.
used primarily for repair and wear applications. n Metco 450P is a combustion powder spray material for
n For corrosive wear applications below 650 °C (1200 °F), oxidation resistant bond coats up to 800 °C (1470 °F).
Diamalloy 1008 is a stainless steel powder that can be
applied using the HVOF spray process.

2.5 Customer Specifications

Product Customer Specifications

Metcoloy 2 American Welding Society (AWS) C2.25/C2.25M W-FeCrNi-9
Honeywell FP 5045, Type V
Rolls-Royce OMAT 3/45
Rolls-Royce OMAT 3/277A
Rolls-Royce plc MSRR 9507/103
Rolls-Royce RRMS40034 Rev. A
Turbine Airfoil Coating and Repair MS 525A
Metcoloy 5 American Welding Society (AWS) C2.25/C2.25M W-FeCrNi-3

3 Coating Information

3.1 Key Thermal Spray Coating Information 3.2 Coating Parameters

n Coating properties can vary significantly as they are de- Please contact your Oerlikon Metco Account Representative
pendant on the chosen equipment, gun hardware, coat- for parameter availability. For specific coating application
ing parameters and coating thickness. ­requirements, the services of Oerlikon Metco’s Coating
n When properly applied, these coatings are designed to ­Solution Centers are available.
achieve the surface hardness necessary for good wear
resistance appropriate for the applications discussed in Recommended Spray Guns
Section 1.1. Electric Arc Wire Combustion Wire
n These coatings are corrosion resistant for various environ-
SmartArc PPG Metco 16E series
ments, as defined in Section 2.3.
LD/Schub 5
n In general, deposit efficiencies of ≥ 70 % can be
achieved, when correctly sprayed. LD/U2
n Coatings are readily machined for dimensional control
and fair surface finishes are achievable.
n See Section 2.3 for additional coating selection criteria.

DSM-0369.1 – FeCr (Cr ≤ 20%) Stainless Steel Thermal Spray Wires

© 2022 Oerlikon Metco 3
4 Commercial Information

4.1 Ordering Information and Availability

Product Order No. Wire Diameter Package Size Package Availability Distribution Origin
Type
Metcoloy 1 1002461 3.2 mm (1/8 in) 25 kg (55 lb) Coil Stock Europe Germany
1002447 4.8 mm (3/16 in) 25 kg (55 lb) Coil Special Order Europe Germany
Metcoloy 2 1031589 1.6 mm (14 ga) 25 lb (11.3 kg) Dorn Spool Stock Global U.S.A.
1002524 1.6 mm (14 ga) 15 kg (33 lb) Wire Basket Stock Europe Germany
1050524 1.6 mm (14 ga) a 15 kg (33 lb) Wire Basket Stock Europe Germany
1002477 1.6 mm (14 ga) b 250 kg (551 lb) Spool (Special) Special Order Europe Germany
1041093 1.6 mm (14 ga) b 15 kg (33 lb) Hasp Spool Stock Europe Germany
1002475 1.6 mm (14 ga) b 15 kg (33 lb) Wire Basket Stock Europe Germany
1002472 2.0 mm (0.08 in) b 15 kg (33 lb) Hasp Spool Special Order Europe Germany
1002520 2.3 mm (11 ga) 25 kg (55 lb) Coil Special Order Europe Germany
1030415 3.2 mm (1/8 in) 50 lb (22.7 kg) Coil Stock Global U.S.A.
1002463 3.2 mm (1/8 in) 25 kg (55 lb) Coil Stock Europe Germany
1059388 3.2 mm (1/8 in) a 25 kg (55 lb) Coil Stock Europe Germany
1030416 4.8 mm (3/16 in) 50 lb (22.7 kg) Coil Stock Global U.S.A.
Metcoloy 4 1002448 1.6 mm (14 ga) 15 kg (33 lb) Wire Basket Stock Europe Germany
1030454 3.2 mm (1/8 in) 50 lb (22.7 kg) Coil Stock Global U.S.A.
1002478 3.2 mm (1/8 in) 25 kg (55 lb) Coil Stock Europe Germany
Metcoloy 5 1031590 1.6 mm (14 ga) 25 lb (11.3 kg) Dorn Spool Stock Global U.S.A
1002525 1.6 mm (14 ga) 15 kg (33 lb) Wire Basket Stock Europe Germany
1000051 3.2 mm (1/8 in) 50 lb (22.7 kg) Coil Stock Global U.S.A
1002499 3.2 mm (1/8 in) 25 kg (55 lb) Coil Stock Europe Germany
1030514 4.8 mm (3/16 in) 50 lb (22.7 kg) Coil Stock Global U.S.A.
Metco 8238 1057868 1.6 mm (14 ga) 13 kg (28.7 lb) Dorn Spool Special Order Europe Germany
a CE (DIN) compliant
b Copper-coated

4.2 Handling Recommendations Product SDS No.

n Store in the original, closed container in a dry location. Metcoloy 1 50-240
Metcoloy 2 50-241
4.3 Safety Recommendations Metcoloy 4 50-242
See the correct SDS (Safety Data Sheet) for the product of
Metcoloy 5 50-220
interest localized for the country where the material will be
Metco 8238 50-1138
used. SDS are available from the Oerlikon web site at
www.oerlikon.com/metco (Resources – Safety Data Sheets).

Information is subject to change without prior notice.

DSM-0369.1 – FeCr (Cr ≤ 20%) Stainless Steel Thermal Spray Wires www.oerlikon.com/metco
© 2022 Oerlikon Metco [email protected]