Issued October 2000

Supersedes April, 1986

TM

Metco 16C Self-Fluxing

Nickel-Chromium Alloy
Powder

Technical Bulletin #10-040


Metco 16C Self-Fluxing Nickel-Chromium Alloy Powder

Metco 16C is one of several self-fluxing alloys which was designed to be fused or remelted in a
normal atmosphere after being sprayed. They then coalesce into a dense, essentially pore-free
coating.

Metco 16C produces coatings which resist wear by abrasive grains, hard surfaces, particle erosion,
fretting, and cavitation. It is useful for nearly all hard-facing applications, especially on irregular
shapes, and where heavy coatings are required. Coatings up to 1/8" (3 mm) or more in thickness may
be fused without difficulty.

Coatings of Metco 16C are similar in wear resistance to coatings of Metco 15E Self-Fluxing Nickel-
Chromium Alloy Powder. They are easier to fuse than coatings of Metco 15E and have less tendency
to crack.

The fused surface of Metco 16C is not quite as smooth as that of Metco 15E. Where a very smooth
as-fused surface is required, a few mils of Metco 15E can be applied over the Metco 16C before
fusing.

Of all of the Metco self-fluxing alloys, Metco 16C and Metco 19E are generally the most resistant to
corrosion.

The Metco self-fluxing alloys were designed to be sprayed with Metco ThermoSpray equipment, and
subsequently fused. Plasma spray equipment also produces useful coatings of these alloys and allow
coatings to be sprayed at higher spray rates than achieved with the ThermoSpray process.

This revision has been issued to include spray parameters for the Type 5P-II and Type 6P-II
ThermoSpray Equipment and Type MBN Plasma Spray Equipment.

Specification Conformance

Metco 16C is certifiable as meeting U.S. Navy Specifications OS 12358, MPR 1031 and MPR 1032.

Applications

Metco 16C is recommended for the following coating functions:

Coating No. Coating Function Typical Applications

T16C-10 Resist abrasive grains Buffing and polishing

P16C-10 (low temperature) fixtures

#10-040 Metco 16C Self-Fluxing Nickel-Chromium Alloy Powder 2

Coating No. Coating Function Typical Applications

T16C-10 Resist abrasive grains Fuel rod mandrels

P16C-10 (high temperature)

T16C-10 Resist hard surfaces Plug gages

P16C-10 (low temperature)

T16C-10 Resist hard surfaces Forging tools

P16C-10 (high temperature)

T16C-10 Resist fretting Cam followers

P16C-10 (intended motion)

T16C-10 Resist cavitation Pumps

P16C-10

T16C-10 Resist particle erosion Exhaust fans

P16C-10 (low temperature)

T16C-10 Resist particle erosion Exhaust valve seats

P16C-10 (high temperature)

Powder Characteristics

Typical Composition: Chromium 16.0%

Silicon 4.0%
Boron 4.0%
Copper 3.0%
Molybdenum 3.0%
Iron 2.5%
Carbon 0.5%
Nickel Balance

Typical Size Range: -120 +325 mesh

Melting Point: 1010C (1850F)

Fusing Temperature: 1065C (1950F)

#10-040 Metco 16C Self-Fluxing Nickel-Chromium Alloy Powder 3

Typical Physical Properties of the Coating

Coatings T16C-10, P16C-10

Texture (microinches aa), as-sprayed: 800-1000

as-fused: 200-300
Finish (microinches aa), ground (60 grit wheel): Less than 10
lapped: 2-3
Typical Macrohardness: Rc60
Porosity: Essentially none
Density (g/cc): 7.5
Bonding: Metallurgical
2
Weight (lb/ft /.001"): .039
2
(kg/m /0.1 mm): .74
Shrinkage During Fusing: 20%
Finish Allowance, inches .002
mm: .05
-6
Thermal Expansion Coefficient: 8-9x10 /F
Plastic Range: Wide

Fusing

Use a Metco Fusing Torch adjusted to produce a soft, slightly reducing flame (gas flow ratio is 3
oxygen: 4 acetylene).

Do not heat a small area of the coating to a high local temperature; the coating may expand rapidly
and separate from the base. Preheat the work evenly from a distance of 100-125 mm (4-5"), moving
the flame back and forth over the surface, to a temperature of 315-540C (600-1000F).

After preheating, move the torch nozzle to a distance of about 11/2" (38 mm) from the work, about 1"
(25 mm) in from the edge of the coating. Oscillate the torch slightly as the fusing point is reached. The
coating will show a glassy shine when it fuses. Do not overheat past this stage; the coating may sag
or run.

When fusing is finished, let the part cool slowly. One way to do this is to bury it in vermiculite in a
metal container. Fast cooling may crack the coating.

Fusing can also be done in a furnace or by induction. See Volume II of the Metco Flame Spray
Handbook for information on these methods.

#10-040 Metco 16C Self-Fluxing Nickel-Chromium Alloy Powder 4

Finishing

Coatings of Metco 16C should be ground to finished size. Recommended wheels, speeds and feeds
may be found in Volume II of the Metco Flame Spray Handbook.

If grinding equipment is unavailable, it may be practical to finish the coatings by machining. Some
machining of Metco 16C coatings, on 50 mm (2") diameter shafts, has been done using a Kennametal
SNG-422, grade K-11, tungsten carbide tool in a KSBR-10 holder. The rough cut was .25 mm (.010")
deep, using a speed of 42 SFPM (12.8 m/min.), and a feed of .38 mm (.015") per revolution. The
finishing cut was .13 mm (.005") deep, speed 63 SFPM (19.2 m/min.), feed 0.2 mm (.008") per
revolution. The coolant was 1:40 soluble oil and water, fed directly onto the tool nose at a rate of one
gallon/hour (3.8 liters/hour).

It should be noted that firm work-holding is essential. The slightest chatter or vibration will break down
the cutting edge of the tool.

On large work, it is not always possible to meet close dimensional tolerances by machining alone, and
a final light grinding operation may be necessary. For example, if .02 mm (.001") of tool wear takes
place over the length of the cut, the diameter of the piece will be .05 mm (.002") greater at the
finishing end than at the starting end. It may be difficult to correct this by machining, although careful
work using a fresh cutting edge permits very light cuts with good accuracy in a precision lathe. Making
minor dimensional corrections with emery cloth or abrasive paper is sometimes possible, but it is very
slow. Stoning with silicon carbide is more effective. A new, flat 200 mm (8") combination stone (coarse
and medium grit), saturated with kerosene or penetrating oil, should be used. The work should be
rotated to give a surface speed of at least 18 m/min. (60 ft./min.). This will provide a good surface
finish and allow fairly close control of dimensions.

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.

#10-040 Metco 16C Self-Fluxing Nickel-Chromium Alloy Powder 5

 System Parameters Thermospray

Set #1 Set#2 Set #3 Set #4

Spray Gun
Type: 2P 5P/5P-II 6P/6P-II 6P/6P-II
(Note 6) (Note 6)
Nozzle: P7 P 7-G/ P 7A-M/ P 7A-K/
P 7B-G P 7C-M P 7C-K
Metering Valve: 1 11 - -

Gas
Pressure - Oxygen, psi: 12 25 32 30
bar: .83 1.7 2.2 2.07
Acetylene, psi: 10 15 15 15
bar: .69 1.0 1.0 1.0
Flow - Oxygen: 24 34 45 42
Acetylene: 28 34 55 50

Powder Feed
Flow Control Valve - clicks open
(Note 1): 8-16 16-18 - -
Unit, 3MP/4MP: - - 3MP/4MP 3MP/4MP
(Note 8) (Note 8)
Meter Wheel: - - S/- S/-
RPM: (Note 7) - - 33/- 45/-
Feed Rate Indicator Setting: (Note 7) - - -/66 -/108
Vibrator Air Pressure, psi: - - -/5 -/5
bar: - - -/.3 -/.3
Nitrogen Carrier Gas Pressure, psi: - - 55 55
bar: - - 3.8 3.8
flow: - - 37 37

Spraying (Note 2)
Spray Distance, inches: 9-10 9-10 8 10
mm: 230-255 230-255 205 255
Spray Rate, 1b/hr: 12 20 (Note 3) 20 35
kg/hr: 5.44 9.1 9.1 15.9
3
Gas Consumption - Oxygen, ft /hr: 35 60 95 82
3
m /hr: 1.0 1.7 2.7 2.2
3
Acetylene, ft /hr: 25 33 59 49
3
m /hr: .71 .93 1.7 1.3
2
Coverage, ft /hr/.001": (Note 4) 280 480 480 830
2
m /hr/0.1 mm: 6.5 11.3 11.3 19.3
2
Powder Weight, lb/ft /.001" (Note 4) .043 .042 .042 .041
2
kg/m /0.1 mm: .82 0.8 0.8 0.8
Deposit Efficiency, %: (Note 5) 95 95 95 95

#10-040 Metco 16C Self-Fluxing Nickel-Chromium Alloy Powder 6

NOTES:
1. Use as a starting point. Individual guns may require settings which fall outside the range. Adjust, as
necessary, to obtain spray rate shown.
2. Spray rates and deposit efficiencies shown were obtained by skilled operators with all equipment in
first-class condition
3. Powder spray rate can be reduced one-half by replacing the No. 11 Metering Valve with the No. 12
Metering Valve.
4. These figures are based on fused coatings.
5. Deposit efficiency figures have been rounded off for easy calculation.
6. Use 4-Jet Siphon Plug Assembly Cat. No. 6P 605 and Cat. No. 6P 4 Air Cap for Type 6P-II; 4-Jet
Siphon Plug Assembly Cat. No. 6P 205 and Cat. No. 6P 4 Air Cap for Type 6P. Set cooling air
pressure at 15 psi (1.03 bar).
7. Use as starting point. Adjust, as necessary, to obtain powder feed rate shown.
8. Use powder port shaft A and black 9-foot powder feed hose when operating Type 4MP.

System Parameters Plasma Spray

SET #5
N2
Spray Gun
Type: MBN
Nozzle: MBN 430
Powder Port: #2
Gas Distribution Ring: MBN 325

Gas
Pressure - Primary, psi: 50
bar: 3.45
Secondary, psi: -
bar: -
Flow - Primary: (Note 1) 60
Secondary -

Power
Unit: MRN
Arc Amps: 500
Arc Volts: 55-65

Powder Feed
Unit: (Note 2) 4MP
Feed Rate Indicator Setting: (Note 3): 120
Vibrator Air Pressure, psi: 5
bar: .3
Carrier Gas Flow: 32

Spraying
Spray Distance, inches: 4-6
mm 100-150
#10-040 Metco 16C Self-Fluxing Nickel-Chromium Alloy Powder 7
Spray Rate, lb/hr: 45
kg/hr: 20
2
Coverage, ft /hr/.001": 1095
2
m /hr/0.1 mm: 26
2
Powder Required, lb/ft /.001": .041
2
kg/m /0.1 mm: .79
Deposit Efficiency, %: (Note 4) 95
Deposition Rate, lb/hr: 42.75

Notes:
1. When zero secondary flow is specified, a minimum of 50 psi (3.4 bar) of pressure is required to
activate the secondary gas pressure switch. The same gas, as used for the primary, may be used
for this purpose. Make sure to keep the secondary flowmeter closed.
2. Use black 9-foot powder feed hose. Use powder port shaft A.
3. With the Type 4MP Powder Feed Unit, feed rates are given as starting points. Adjust to obtain rate
shown.
4. Deposit efficiencies are approximate and have been rounded off for easy calculation. Spray rates
and deposit efficiencies shown were obtained by skilled operators with all equipment in first-class
condition.

Producing Recommended Coating

Coating No.: T16C-10

Surface Preparation: Use any standard method, except bond coat.
Spraying: Parameter Set Nos. 1, 2, 3, 4
Fusing: Fuse per instructions in this Technical Bulletin.
Finishing: Grind

Coating No.: P16C-10

Surface Preparation: Use any standard method, except bond coat.
Spraying: Parameter Set. No. 5
Fusing: Fuse per instructions in this Technical Bulletin.
Finishing: Grind

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.

#10-040 Metco 16C Self-Fluxing Nickel-Chromium Alloy Powder 8