Issued October 2000

Supersedes December, 1979

TM

Metco 445 Self-Bonding

Aluminum-Bronze Powder

Technical Bulletin #10-132

 Metco 445 Self-Bonding Aluminum Bronze Powder

Summary: Metco 445 is a Copper-Aluminum composite powder which was especially developed to
produce self-bonding, good wear resistance, Aluminum-Bronze type coatings for soft-bearing
applications. This material offers two major advantages: One-Step spraying and High Integrity coatings.

One-Step coatings offer these benefits:

Eliminate the need for a separate bond coat.

Less undercutting required. The allowance for 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 445 was designed to produce coatings which have high abrasive wear resistance as compared
to existing Metco aluminum-bronze materials. Coatings of Metco 445 will resist abrasive wear from
hard surfaces at low temperatures. They are recommended for salvage and buildup applications on
copper alloy substrates. They make excellent soft-bearing surfaces.

Features

Metco 445 can be sprayed with minimum dependence on technique. Coatings of unlimited thick-
ness can be applied. The properties of the coatings produced with Metco 445 provide a number of
additional benefits.

Good Bond Strength- Coating tensile bond strengths of 3,000 psi (2070 N/cm2) with ThermoSpray,
and 3,000 psi (2070 N/cm2) with Plasma, are typical.

Good Wear Resistance- Resistance to abrasive wear is 2-3 times better than coatings of Metco 51 or
combustion-sprayed Sprabronze AA.

Low Shrink- Coatings of unlimited thickness can be applied without cracking, which makes Metco
445 ideally suitable for machine-element applications.

Good Finishing Capability- Coatings of Metco 445 can be easily machined to finishes ranging from
good to excellent.

Metco 445 can be sprayed with either the Metco Type 5P or 6P ThermoSpray Guns, and with the
Metco Plasma Flame Spray System. Metco 445 is not recommended for use with a Metco Type N
Gun because of the amount of smoke generated.

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Applications

Metco 445 is recommended for the following applications:

Coating No. Coating Function Typical Applications

T445-10 Salvage and buildup Worn or mis-machined parts
P445-10 on copper alloys

T445-10 Soft-bearing surfaces Piston guides

P445-10

T445-10 Resist Fretting Press fits, bearing seats

P445-10 (No intended motion
low temperature)

T445-10 Resist Hard Surfaces Shifter forks, brake drums

P445-10 (low temperature)

Coating Selection

Coating T445-10 can be produced with either a Type 5P, 5PT Extension or 6P Gun. Coating P445-10
can be produced with either a 3M or 7M Plasma System.

P445-10 Coatings are slightly more dense than T445-10 Coatings, and will exhibit wear resistance
and corrosion resistance properties equal or better than T445-10 Coatings.

Powder Characteristics

Typical Composition: Aluminum 10%

Copper Balance

Typical Size Range: -140 + 325 mesh

-106 +45 microns

Melting Point: 660 C (1215 F)

Aluminum Constituent

Typical Physical Properties

T445-10 P445-10
Texture, as sprayed,
microinches aa (microns): 450-650 (11-17) 500-800 (12.7-20)
Finish, machined
microinches aa (microns): 35-45 (.9-1.1) 35-50 (.9-1.3)
Macrohardness: Rb50 Rb50
Density (g/cc): 6.7 6.7
Porosity (Volume %): less than 3% less than 3%

#10-132 Metco 445 Self-Bonding Aluminum-Bronze Powder 3

Oxide Content (Volume %): 12% 7%

Coating Weight (lb/ft2/.001): .035 .035

(kg/m2/0.1mm): .67 .67

Tensile Strength (perpendicular to

the direction of spraying): psi 16,000 16,000
N/cm2: 11,000 11,000
Bond Strength, Low Carbon Steel
Substrate, ground, psi: 3,000 3,000
N/cm2: 2,070 2,070
Metcolite C Blast, psi: greater than 3,500 ---
N/cm2: greater than 2,410 ---
Free Cutting Brass & Bronze, ground,
psi: 3,000 3,000
N/cm2: 2,070 2,070
Metcolite C Blast, psi: greater than 3,000 ---
N/cm2: greater than 2,070 ---

Bond Strength

Metco 445 is similar to Metco 450 in that the self-bonding property is a direct result of the exothermic
reaction which takes place between the copper and aluminum constituents. The heat generated by
this reaction not only assures consistent bonding, but also causes better interparticle bonding which
results in greater coating integrity.

On ground substrates of low carbon steel and free-cutting brass and bronze, bond tests conducted in
accordance with ASTM C 633 indicate that self-bonding tensile strengths, in excess of 2,000 psi
(1380 N/cm2), are typical for coatings applied with ThermoSpray; and self-bonding tensile strengths,
in excess of 3,000 psi (2070 N/cm2), are typical of plasma sprayed coatings.

Metco 445 is not self-bonding to materials where Metco 405 or Metco 450 are not self-bonding, such
as pure copper substrates.

Thickness Limitation

There is no thickness limitation. Heavy buildup of Metco 445 coatings can be applied without cracking.

Maximum Service Temperature

Similar to other copper base alloys, exposing Metco 445 coatings to temperatures in excess of 230 C
(450 F) in service can result in excessive oxide formation, which will adversely affect the internal
strength of the coating.

#10-132 Metco 445 Self-Bonding Aluminum-Bronze Powder 4

Wear Resistance

Standard laboratory slurry abrasive wear tests showed that Metco 445 coatings exhibit 2-3 times
better abrasive wear resistance than either Metco 51 coatings or combustion-sprayed Sprabronze AA
1
coatings. Also, Metco 445 coatings exhibit 1-1 /2 times better abrasive wear resistance than arc-
sprayed Sprabronze AA.

The improved wear resistance is the result of a higher oxide content, and the presence of hard copper-
aluminide particles in the coating.

Corrosion Resistance

Metco 445 coatings are not recommended for general use in applications where corrosion resistance
equal to that of an aluminum-bronze alloy coating, is of primary importance. The presence of some free
(unreacted) aluminum in the coating could cause internal corrosion in some atmospheres.

Metco 445 coatings readily oxidize. If coated parts are to be stored for any period of time, prior to use,
it is recommended that they be coated with a film of mineral oil, compatible with aluminum and copper.

Surface Preparation

Coatings of Metco 445 are self-bonding. When they are used for the presently recommended coating
functions, thorough cleaning of the substrate is the only preparation necessary. Surface oxidation must
be removed, and preheating to prevent the formation of condensate is required.

Metco 445 coatings have been successfully machined to a feather-edge. However, for such applications,
it is recommended that the substrate be roughened by at least grit blasting.

Spraying

To produce Metco 445 coatings with their outstanding characteristics, the recommended spraying
parameters must be followed.

Preheat: Normal 90-120 C (200-250 F)

Typical Application Rate: 0.1mm (0.004) per pass
Maximum Temperature: 230 C (450 F)

Both the spray rate and the spray distance are critical variables in the proper spraying of Metco 445.
Excessively fast spray rates or spray distances less than the recommended values will inhibit the
exothermic reaction needed to produce the excellent bond and internal strength typical of Metco 445
coatings.

Note: Coatings Produced with Plasma Extensions:

The information compiled in this bulletin pertains to coatings produced by Metco 3MB, 7MB and
ThermoSpray Guns. The coatings produced by plasma extensions may vary in comparative quality.
Coatings of Metco 445 produced by plasma extensions may be softer due to a lower amount of oxides
than standard 3MB/7MB coatings.

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Finishing

Metco 445 coatings can be machined to excellent finishes using standard carbide tools. Good
machined finishes were obtained over a wide range of work speeds.

Good results on both large and small diameter shafts were obtained by dry machining under the
following conditions:

Tools: Kennametal D Shape K68 Carbide Tool .75mm (.030)

radius positioned perpendicular to center line of shaft

Work Speed: 3.1-4.1m/sec (600-800 SFPM)

Traverse Speed: .04mm/rev .0017/rev

Infeed: .25mm (.010) roughing

.13mm (.005) finish cut

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 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.

System Parameters ThermoSpray

SET #1 SET #2
Spray Gun:
Type: 5P with 5PT 5P 6P
Nozzle: P7-F P7-B P7A-M
Siphon Plug: Standard Standard 6P 205
Air Cap: Standard Standard 6P 3
Metering Valve: 15 15 N/A
Vibrator: Yes Yes N/A

Gas:
Pressure - Oxygen, psi: 30 30 40
bars: 2.1 2.1 2.8
Acetylene, psi: 15 15 15
bars: 1.0 1.0 1.0
Flow - Oxygen: (Note1) 30 33 45
Acetylene: (Note 1) 36 33 55

#10-132 Metco 445 Self-Bonding Aluminum-Bronze Powder 6

Air Cooling: (Note 2)
Pressure, psi: 35 20 20
bars: 2.4 1.4 1.4

Powder Feed:
Flow Control Valve -
clicks open: (Note 3) 6-10 6-10 N/A
Unit: N/A N/A 3MP
Meter Wheel: N/A N/A S
RPM: (Note3) N/A N/A 12
Nitrogen Carrier Gas -
Pressure, psi: N/A N/A 55
bars: N/A N/A 3.8
Flow: N/A N/A 37

Spraying: (Note 4 and 5)

Spray Distance, inches: 4-7 4-7 4-7
mm: 100-175 100-175 100-175
Spray Rate, lb/hr: 6 6 5
kg/hr: 2.7 2.7 2.3
Gas Consumption - Oxygen, ft3/hr: 51 56 95
m3/hr: 1.4 1.6 2.7
Acetylene, ft3/hr: 36 32 59
m3/hr: 1.0 .91 1.7
Nitrogen, ft3/hr: N/A N/A 10
m3/hr: N/A N/A 2.8
Coverage, ft2/hr/.001": 146 146 128
m2/hr/0.1mm: 3.4 3.4 3.0
Powder Required, lb/ft2/.001": .04 .04 .039
kg/m2/0.1mm: .79 .79 .75
Deposit Efficiency: (Note 6) 85% (Note 7) 85% 90%

Notes:
1. Type 2GF Flowmeter. When using Type GF Flowmeter, reduce pressure for oxygen 10 psi (.69 bars)
and also reduce pressure for acetylene 2-4 psi (.14-.28 bars) to obtain flowmeter readings shown.
2. Orient Air Cap with cool side out.
3. Use as a starting point. Powder flow rate is critical. Adjust as necessary to obtain rate shown.
4. Some deposit may form on the face of the nozzle when spraying for extended periods. The nozzle
face should be wiped at regular intervals. Do not file or scrape.
5. For the best bond, preheat recommendations should be followed.
6. Deposit efficiencies shown are approximate and have been rounded off for easy calculation.
7. Deposit efficiencies shown in the Type 5PT spray table are for an 80 spray head. A 45 spray head
will lower the deposit efficiencies by five to fifteen percent.
8. Spray rates and deposit efficiencies shown were obtained by skilled operators with all equipment in
first-class condition.

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System Parameters Plasma Flame

SET #3 SET #4 SET #5

N2/H2 A/H2 N2
Spray Gun:
Type: 3MB/7MB 3MB/7MB 7MB
Nozzle: G GH 707
Powder Port: #1 #2 #2
Uni-Jet Ring: (Note 1) N/A 3M 275 N/A
Insulator: (Note 2) 7M 55 7M 50 7M 55

Gas:
Pressure - Primary, psi: 50 100 75
bars: 3.45 6.89 5.17
Secondary, psi: 50 50 Note 4
bars: 3.45 3.45 ---
Flow - Primary: 150 80 150
Secondary: 15 (Note 3) 15 (Note 3) -0- (Note 4)

Power:
Unit: (Note 5)
Arc Amps: 500 500 400
Arc Volts: 74-80 64-70 60-70

Powder Feed:
Unit: 3MP 3MP 3MP
or 3MP-Dual or 3MP-dual or 3MP-dual
Meter Wheel: H H H
RPM: (Note 6) 25 25 30
Carrier Gas Flow: 37 37 37

Spraying:
Spray Distance, inches: 4-6 2-3 4-6
mm: 100-150 50-75 100-150
Spray Rate, lb/hr: 20 20 25
kg/hr: 9.1 9.1 11.3
Coverage, ft /hr/.001":
2
400 400 530
m2/hr/0.1mm: 9.5 9.5 12.5
Powder Required, lb/ft2/.001": .050 .050 .047
kg/m2/0.1mm: .96 .96 .91
Deposit Efficiency: (Note 7) 70% 70% 70%
Deposition Rate, lb/hr: 14.0 14.0 17.5
kg/hr: 6.4 6.4 7.9

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Notes:
1. With the Type 3MB Gun, use Cat. No. 3M 275 Uni-Jet Ring with the Cat. No. 3M 276 Electrode Nut.
Install ring with the 45 internal recess facing the nut and with the jet hole toward the top of the gun,
approximately 180 from the gas inlet.
2. With the Type 7MB Gun, use Cat. No. 7M 50 Insulator with Argon, and Cat. No. 7M 55 Insulator
with Nitrogen.
3. The secondary gas flow shown in the chart may be adjusted as much as +5 points, if necessary to
obtain voltage within the range shown; except that the secondary gas flow may not be reduced to
zero, and hydrogen flow may not exceed 25. If the required voltage is not obtained with the preliminary
gas flow adjustment, check the equipment for a worn nozzle, a worn electrode, or a gas leak between
the flowmeter and the gun. If there is no gas leak, and the nozzle and electrode are not badly worn,
further adjustment of the secondary gas flow, up to an additional +5 points, is permissible, if this
second adjustment does not result in a flow of zero or a hydrogen flow exceeding 25. If the required
voltage is not then obtained, replace the worn parts.
4. When zero secondary flow is specified, 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.
5. The Metco Type 2MR, 4MR, 6MR, or 7MR Power Supply Units can be used. Caution: When using
the Type 6MR and 7MR units with a Type 3MB Gun, do not exceed 40kw operation.
6. Use as starting point. Adjust as necessary to obtain spray rate shown.
7. Rounded off for easy calculation.
8. Spray rates and deposit efficiencies shown were obtained by skilled operators with all equipment in
first-class condition.

System Parameters Plasma Flame

Producing Recommended Coatings:

Coating No. T445-10 P445-10

Surface Preparation: Any standard method Any standard method
Spraying: Parameter Sets No. 1 or 2 Parameter Sets No. 3, 4 or 5

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.

#10-132 Metco 445 Self-Bonding Aluminum-Bronze Powder 9