AWS C2.25/C2.

25M:2002
An American National Standard

Specification for
Thermal Spray
Feedstock—Solid
and Composite
Wire and Ceramic
Rods

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Copyright American Welding Society

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 Key Words—Thermal spray, feedstock, ferrous, AWS C2.25/C2.25M:2002
nonferrous, ceramic rod, chemical An American National Standard
composition, solid and composite
wires
Approved by
American National Standards Institute
April 23, 2002

Specification for

Thermal Spray Feedstock—

Solid and Composite Wire
and Ceramic Rods

Prepared by
AWS C2 Committee on Thermal Spray

Under the Direction of

AWS Technical Activities Committee

Approved by
AWS Board of Directors

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

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 Statement on Use of AWS American National Standards
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International Standard Book Number: 0-87171-656-9
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© 2002 by American Welding Society. All rights reserved

Printed in the United States of America

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On occasion, text, tables, or figures are printed incorrectly (errata). Such errata, when discovered, are shown on the
American 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- -
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ing, to the Managing Director Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126
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(see Annex B). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may ,
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be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. These `
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individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpre-
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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 every
five years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations, additions, or
deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to
AWS Headquarters. Such comments will receive careful consideration by the AWS C2 Committee on Thermal Spray
and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to
attend all meetings of the AWS C2 Committee on Thermal Spray to express their comments verbally. Procedures for
appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical
Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune

Road, Miami, FL 33126.

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 Personnel
AWS C2 Committee on Thermal Spray
E. Rybicki, Chair The University of Tulsa
T. 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 Laboratory
C. 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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 AWS C2J Subcommittee on Surfacing Materials for Thermal Spraying

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J. B. C. Wu, Chair Deloro Stellite Co., Inc.
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R. A. Sulit, Vice Chair Sulit Engineering
E. F. Mitchell, Secretary
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American Welding Society
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C. Arata Anval Inc.

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G. A. Croopnick Amphorous Technologies International
M. R. Dorfman Sulzer-Metco
R. A. Douty Bechtel Bettis Laboratory
G. 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

iv
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 Foreword
(This Foreword is not a part of AWS C2.25/C2.25M:2002, Specification for Thermal Spray Feedstock—Solid 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 or
ceramic rod from one manufacturer is interchangeable with that from another. The classification tests permit identification
of similar thermal spray wires and ceramic rods.
This specification was developed pursuant to a request from the U.S. Army Material Technology Center to incorporate
MIL-W-6712C, Metallizing Wire, as an American Welding Society Standard.

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 --``,``-`-`,,`,,`,`,,`---

Copyright American Welding Society

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No reproduction or networking permitted without license from I HS Not for Resale
 Table of Contents
Page No.
Personnel .................................................................................................................................................................... iii
Foreword.......................................................................................................................................................................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

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5. Certification...........................................................................................................................................................2
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6. Test Methods and Retest ......................................................................................................................................2
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6.2 Retest ............................................................................................................................................................2

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

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

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

10. Standard Packaging Forms ....................................................................................................................................9

10.1 Coils with Support ........................................................................................................................................9
10.2 Spools............................................................................................................................................................9
10.3 Ceramics Rods ............................................................................................................................................ 10

11. Winding Requirements.................. ...................................................................................................................... 10

11.1 Winding.......................................................................................................................................................10
11.2 Cast and Helix.............................................................................................................................................10
12. Solid and Composite Wire and Ceramic Rod Identification ...............................................................................11

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

14. Marking of Packages................. ..........................................................................................................................12

14.1 Product Information ....................................................................................................................................12
14.2 Precautionary Information ......................................................................................................................... 12

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

vii
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 List of Tables
Table NoP. age
1 Chemical Composition Requirements for Solid Ferrous Thermal Spray Wires............ ................................3
2 Chemical Composition Requirements for Solid Nonferrous Thermal Spray Wires.............. ........................4
3 Chemical Composition Requirements for Cored Composite Thermal Spray Wires ..................................... 6
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4 Chemical Composition Requirements for Thermal Spray Ceramic Rods .....................................................7
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5 Standard Sizes for Thermal Spray Wires .......................................................................................................9
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6 Standard Sizes for Thermal Spray Ceramic Rods......... .................................................................................9

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7 Standard Packaging Dimensions and Weight for Thermal Spray Wires......................................................10

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List of Figures
Figure No
P.age
1 Thermal Spray Feedstock Classification System Format ..............................................................................8
2 Dimensions of Standard 12- and 14-i n. [300- and 350-m m] Spools ...........................................................11
3 Dimensions of Standard 22-, 24-, and 30-in. [560-, 610-, and 760-mm) Spools.........................................12
A1 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

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Specification for Thermal Spray Feedstock—

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Solid and Composite Wire and Ceramic Rods

1. Scope (4) ASTM E 354, Test Method for Chemical Analysis

This 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 the
scope of this standard and, therefore, are not fully ad-
dressed herein. Some safety and health information is
available from other sources, including, but not limited
to, ANSI Z49.1, Safety in Welding, Cutting, and Allied
Processes, and applicable federal and state regulations.
This specification makes use of both U.S. Customary
Units and the International System of Units (SI). The
measurements are not exact equivalents; therefore, each
system must be used independently of the other without
combining in any way when referring to thermal-spray
feedstock and the deposited coating. The specification
with the designation C2.25 uses U.S. Customary Units.
The specification C2.25 M uses SI Units. The latter are
shown within brackets [ ] or in appropriate columns in
tables and figures.
of 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 Alloys
in the Unified Numbering System
The following AWS2 standard is referenced in the
mandatory 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 Welding—Size
Requirements

2. Reference Documents
The following ASTM1 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 with
Specifications
(2) ASTM E 34, Test Method for Chemical Analysis
of 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.
3. Significance and Use
This specification defines the as-manufactured chemi-
cal composition classification requirements for solid and
composite 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 Engineering
Documents, 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 National
Standards Institute, 11 West 42nd Street, New York, NY
10036-8002.

1
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 AWS C2.25/C2.25M:2002

This specification may be used to classify and procure cordance with the round-off method given in ASTM E 29,
solid and composite wire and ceramic rods for thermal Standard practice for Using Significant Digits in Test
spraying. Data to Determine Conformance with this Specification.

4. Basis of Cl assification 6. Test Methods and Retest

4.1 The thermal-spray solid and composite wires, and ce- 6.1 Chemical Analysis
ramic rods in this specification are classified using a sys-
6.1.1 The chemical compositions of ferrous and non-
tem that is independent of U.S. Customary Units and the
ferrous solid and composite wire and ceramic rod feed-
International System of Units (SI). The classification is
stock are defined in Tables 1, 2, 3, and 4. The chemical
according to chemical composition of the thermal-spray
composition shall be determined by emission spectro-
material as specified in Tables 1 through 4. Table 1 lists
chemical analysis, inductively coupled plasma spectros-
the chemical composition of solid ferrous wires. Table 2 copy, and wet chemical analysis, singly or in
lists the chemical composition of solid nonferrous wires.
combination, in accordance with one or more of the fol-
Table 3 lists the chemical composition of the mixture of
lowing standards, or as agreed to by the purchaser and
the sheath and core material of composite wires. Table 4
supplier:
lists the chemical composition of ceramic rods.
(1) ASTM E 34, Test Method for Chemical Analysis
4.2 The system for classifying the thermal-spray feed-
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of Aluminum and Aluminum Alloys (referee)

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stock under this AWS standard is using W, CW, and CR

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(2) ASTM E 227, Standard Method for Optical Emis-
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as the prefix designation for solid-alloy and solid- sion Spectrometric Analysis of Aluminum and Aluminum
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composite wires, cored-composite wires, and ceramic

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Alloys by the Point-to-Plane Technique

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rods respectively, followed by the chemical composition
in decreasing percentage order (see Figure 1).
4.3 Thermal-spray solid and composite wires and ceramic
rods classified under one classification shall not be classi-
fied under any other classification in this specification.
5. Certification
5.1 The act
fication of placing the
designations on C2.25 specification
the packaging and classi-
enclosing the
product, or the classification on the product itself, consti-
tutes the supplier’s (manufacturer’s) certification that the
product 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 conducted
the tests required by the specification on material that is
representative of that being shipped and that material met
the 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 were
necessarily conducted on samples of the specific material
shipped. Tests on such material may or may not have
been conducted. The basis for the “certification” required
by the specification is the classification test of “represen-
tative material” cited above, and the “Manufacturer’s
(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 Analysis
of 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) Cored Composite Wires and Ceramic Rods.A rep-
resentative sample obtained from a melt or a firing of a
representative 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 as
agreed by the purchaser and supplier.
6.1.3 The sample shall be analyzed by accepted ana-
lytical methods. For elements not covered by the above
listed test methods, the referee test method per ASTM
E 34, shall be used or as otherwise agreed upon between
the manufacturer and the purchaser.

Quality Assurance Program.” 6.2 Retest

5.3 For the purpose of determining conformance with this 6.2.1 If the results of any test fail to meet the require-
specification, an observed or calculated value shall be ment, that test shall be repeated twice. The results of both
rounded to the nearest unit in the right-hand place figures retests shall meet the requirements. Specimens for retest
used in expressing the limiting values for quantities in ac- may be taken from the srcinal sample. For chemical

2
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 AWS C2.25/C2.25M:2002

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Provided by IHS under license with AWS
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2 e R R R R R R R R R R R R R R R R o )1
C D C C C C C C C C C C C C C C C C N (

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 AWS C2.25/C2.25M:2002

W — for solid alloy and solid composite wires

P re f i x L e t t e r ( s)  CW— for cored composite wires
 CR — for ceramic rods

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

of the solid and cored wires, ceramic rods, or the Aluminum

Major chemical elements in percentage order
Association alloy designation

Dash to separate similar chemical compositions from the suffix number

in solid wires, cored wires, and ceramic

Suffix number to differentiate similar chemical compositions
rods

in a metal matrix composite

Major chemical composition of the ceramic material

-
-
-
`

XX - xxxx - N - yyyy ,
,
`
,
`
,
,
`
,
,

Examples: `
-
`
-
`
`
,

A. W-FeC-2 — The second ( 2) carbon steel ( FeC) solid wire. `

`
-
-

B. W-Al-Al2O3 — 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-ZrO2-3 — The third ( 3) zirconium oxide (ZrO2) ceramic rod.

Figure 1—Thermal Spray Feedstock Classification System Format

analysis, retest need be only for those specific elements
that 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.
coils without support, spools, and drums, and straight
lengths for ceramic rods—see Section 10) are shown in
Tables 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,

6.2.2 In the event that, during preparation or after
completion 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, the
test shall be considered invalid, without regard to
whether the test was actually completed, or whether test
results met, or failed to meet, the requirement. That test
shall 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 ceramic
rods classified according to this specification may be
manufactured by any method, which meets the require-
ments of this specification.
8. Standard S izes
Standard sizes for thermal-spray wires and ceramic
rods in the different package forms (coils with support,
i.e., the spray gun nozzle diameter, should be specified.
9. Finish and Uniformity
The 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 wire
feedability or the properties of the thermal-spray wire.
(2) Each continuous length of thermal-spray wire
shall be from a single heat or lot of material. Welds,
when present, shall be made so as not to interfere with
the uniform, uninterrupted feeding of the thermal-spray
wire in automatic or semiautomatic equipment.
(3) Cored composite wires shall have the core ingre-
dients evenly distributed throughout their length so as not
to adversely affect the performance of the thermal-spray
wire, 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.

8
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 AWS C2.25/C2.25M:2002

Table 5
Standard Sizes for Thermal Spray Wires
Wire
Diameter Tolerance

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

Standard Package Form in. mm in. mm

Coils With and 0.045 +0.001 –0.002

Without Support 0.047 1.2 +0.001 –0.002 +0.03 –0.06
0.055 1.4 +0.001 –0.002 +0.03 –0.06
(1)
0.059 1.5 (1) +0.001 –0.003 +0.03 –0.08
0.063 1.6 +0.001 –0.003 +0.03 –0.08
0.078 2.0 +0.001 –0.003 +0.03 –0.10
(1)
Drums 0.091 2.3 (1) +0.001 –0.004 +0.03 –0.10
0.094 2.4 +0.001 –0.004 +0.03 –0.11
Spools 0.125 3.2 +0.002 –0.004 +0.03 –0.13
0.156 4.0 +0.002 –0.004 +0.03 –0.13
(1)
0.188 4.8 (1) +0.002 –0.004 +0.03 –0.13
0.196 5.0 +0.002 –0.004 +0.03 –0.13
Note:
(1) Metric sizes not shown in ISO 544.

Table 6
Standard Sizes for Thermal Spray Ceramic Rods
Rod
Diameter Tolerance

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

Standard Package Form in. mm in. mm

100 pieces 0.183 4.6 +0.005 –0 +0.13 –0

100 pieces 0.244 6.2 +0.005 –0 +0.13 –0
50 pieces 0.307 7.8 +0.005 –0 +0.13 –0

(5) Subject to agreement between the purchaser and
the supplier, a very small amount of specified lubricant
that 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 Pack aging Forms
and weights other than these shall be as agreed upon
between 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 coil
during normal handling and use. They shall be clean and
dry to maintain the cleanliness of the thermal-spray wire.

Standard packaging forms are (a) coils with and with-
out support, drums, and spools for solid and composite
wires and (b) straight lengths for ceramic rods. Standard
package dimensions and weights for the thermal-spray
wires are given in Table 7. Dimensions for standard
spools are given in Figures 2 and 3. Package forms, sizes,
10.2 Spools
10.2.1 Spools shall be designed and constructed to
prevent distortion of the spool and thermal-spray wire
during normal handling and use. They shall be clean and
dry to maintain the cleanliness of the thermal-spray wire.

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 AWS C2.25/C2.25M:2002

Table 7
(1)
Standard Packaging Dimensions and Weights for Thermal Spray Wires
(2)
Package
Size Net
Weight

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

Type of Package in. (diameter) mm lb kg

Coils
Without
Support (3) (3)

CoilsWithSupport 12 Inside 300 25, 30, 50, and 60 10, 15, 20, and 25
12 ± 1/8 Inside 300 ± 3 25 and 30 10 and 15
12 ± 1/8 Inside 300 ± 3 50, 60, and 65 20, 25, and 30

Drums .015.5 Outside 400 (3)

20 Outside 500 (3)
-
-
23 Outside 600 300and600 140 and 270
`
`
,
`
`

Spools 12 Outside 305 15–45 10–20

-
`
-
`
,
,
`
,
,
`
,
14 Outside 355 50 and 60 20 and 30
`
,
,
`
-
22 Outside 560 250 110
-
-

24 Outside 610 300 140

30 Outside 760 600, 750, and 1000 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.

The use of insulated spools shall be agreed upon between 11.1.2 Coils without support shall be wound with a
purchaser and supplier. left-hand configuration so that when the coil is laid hori-
zontal with the beginning end tag up, the coil will un-
10.3 Ceramic Rods wind in a counterclockwise direction.

10.3.1 Ceramic rods shall be packaged in impact re-

sistant tubular containers to prevent breakage during
shipment.
11. Winding Req uirements
11.1 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 unwind
without restriction. The outside end of the thermal-spray
wire (the end with which thermal spraying is to begin)
shall be identified so it can be located readily and shall
be fastened to avoid unwinding. The outermost layer on
spools shall be at least 1/8 in [3 mm] from the rim of the
flanges of the spool.
11.2 Cast and Helix
11.2.1 The cast and helix of thermal-spray wires in
coils, 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 on
12 in. [300 mm] spools shall be such that a specimen
long enough to produce a single loop, when cut from the
spool and unrestrained on a flat surface will:
(1) Form a circle not less than 15 in. [380 mm] nor
more 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.

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 AWS C2.25/C2.25M:2002

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

in. mm in. mm
A Spool
Diameter,
maximum 12 305 14 355
Spool Width 4.0 103 4.0 103
B
Tolerance ±0.06 –3, +0 ±0.6 –3, +0
Barrel Diameter 2.03 50.5 2.03 50.5
C
Tolerance –0, +0.06 –0, +2.5 –0, +0.06 –0, +2.5
Distance between Axes 1.75 44.5 1.75 44.5
D
Tolerance ±0.02 ±0.5 ±0.02 ±0.5
Driving Hole Diameter 0.44 10 0.44 10
E
Tolerance (Note 2) –0.06, +0.0 –0, +1 –0.06, +0.0 –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 a
plus tolerance only, which is shown here as a maximum.

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

12. Solid and Composite Wire and
Ceramic Rod I dentification
The product information (14.1) and the precautionary
information (14.2) shall be placed on each coil, spool, or
drum of wire and on each package of ceramic rods.
(1) Coils without support shall have a tag containing
this information securely attached to the thermal-spray
wire 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 in
a prominent location on the outside of at least one flange
of the spool.
Drums shall have the information securely affixed in a
prominent location on the side of the drum.
Packages of ceramic rods shall have the information
securely affixed in a prominent location on the side of the
package.
13. Packaging
Thermal-spray products shall be suitably packaged to
ensure against damage during shipment and storage
under normal conditions.

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

in. mm in. mm in. mm
A Spool
Diameter,
maximum 22 560 24 610 30 760
B Spool
Width,
maximum 12 305 13.5 345 13.5 345
Center Hole Diameter 1.31 35.0 1.31 35.0 1.31 35.0
C
Tolerance –0, +0.13 ±1.5 –0, +0.13 ±1.5 –0, +0.13 ±1.5
Distance, Center to Center 2.5 63.5 2.5 63.5 2.5 63.5
D
Tolerance ±0.13 ±3 ±0.13 ±1.5 ±0.13 ±3
Driving Hole Diameter 0.69 16.7 0.69 16.7 0.69 16.7
E
Tolerance (Note 1) –0.06, +0 ±0.7 –0.06, +0 ±0.7 –0.06, +0 ±0.7

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 the
inside 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.

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

14. Marking of Packages (3) Size and net weight.

(4) Lot, control, or heat num ber.
14.1 Product Information

14.1.1 The following product information, as a mini- 14.2 Precautionary Information

mum, shall be legible and visible from the outside of
each unit package: 14.2.1 The appropriate precautionary information given
(1) C2.25 specification and classification designation in ANSI Z49.1 latest edition (as a minimum) shall be
(year of issue may be excluded). prominently displayed in legible print on all packages, in-
(2) Supplier’s name and trade designation. cluding individual unit packages within a larger package.

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 AWS C2.25/C2.25M:2002

Nonmandatory Annexes

Annex A
Guide 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.)

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, and
the 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 the
following:
(1) Volume of space in which the thermal spraying
operation is to be done
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 is
required in spraying and blasting operations that are not
performed in the open or in a properly designed and ven-
tilated room. Otherwise, the dust will rapidly fill a large
tank, building, or semi-enclosed space.
The ventilation equipment for most field thermal
spray and blast operations consists of engine- or motor-
or air- (venturi) driven portable exhausters with flexible
piping or ducts. This removes the dust rapidly and allows

(2)
(3) Number of spray
The evolution and grit blast
of hazardous operators
fumes, gases, or dusts
depending on what type of abrasive process is used or
material being sprayed
(4) Heat generated by the spraying process
(5) Presence of volatile solvents
All 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 should
be provided to control toxic fumes, gases, or dusts, and
their removal from the work area.
Where thermal spraying operations are incidental to
general 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
operators suitable
deficiencies, visibility.should
and operators Systems of respiratory
wear this type have
de-
vices approved by the U.S. Bureau of Mines, NIOSH, or
other 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 is
necessary to attach a dust collector to trap the dust and
prevent contamination of the surrounding areas.
In shop environments, use wet (water wash), bag, or
filter type collectors for gathering spray dust. Dust col-
lectors must be replaced and ventilation ducts kept clean
before entrapped dust builds up to create an explosion
hazard 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 be
mounted at the edge of the carriage so that it travels with
the gun. This allows the dust and fumes to be exhausted
into the dust collector. The gun is aimed so that the

5. CGA documents can be obtained from the Compressed Gas

4. ANSI standards can be obtained from American National Stan- Association, Inc., 1725 Jefferson Davis Hwy., Suite 1004,
dards Institute, 11 West 42nd Street, New York, NY 10036-8002. Arlington, VA 22202-4102.

13 --``,``-`-`,,`,,`,`,,`---

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 AWS C2.25/C2.25M:2002
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 m2], and the velocity of the air entering the opening
should be a minimum of 200 ft/min [1 m/sec]. The hood
opening should eliminate turbulence along the sides that
could force the spray dust into the operator’s breathing
zone. 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 hood
can be hinged, permitting use of a crane for loading or
unloading. In automatic and production spraying, the en-
tire mechanism is often totally enclosed, and the dust is
exhausted into a water wash and collecting system. In-
dustrial Ventilation, published by the American Confer-
ence of Governmental Industrial Hygienists, should be
consulted.
During dry grinding or lapping operations on sprayed
coatings, precautions should be taken to provide proper
exhaust equipment. ANSI/ASC Z43.1, Ventilation Con-
trol of Grinding, Polishing, and Buffing Metals , should
be consulted.
Spray cabinets used for spraying small and medium
size 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 that
turbulent eddy currents are eliminated. When spraying
toxic 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 lighted
and adequately ventilated. Ventilation should provide
down draft and longitudinal airflow with a velocity of
80 to 100 ft/min [0.2 to 0.5 m/sec]. The blasting room
should be equipped with a dust-collecting system. This is
6. ACGIH documents can be obtained from the American
Conference of Governmental Industrial Hygienists, 1330
Kemper Meadow Drive, Suite 600, Cincinnati, OH 95240-
1634.
14--``,``-`-`,,`,,`,`,,`---
Copyright American Welding Society
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No reproduction or networking permitted without license from I HS
usually required by local ordinances. Further, local, state,
and federal regulations should be investigated before ex-
hausting directly into the atmosphere. The blasting room
may also occasionally be used for spraying. This is not
good practice and should be avoided whenever possible.
Spray dust will quickly clog most cloth dust collectors
used in the blasting rooms. Moreover, when spraying in a
blasting room, the dust-collector system will require more
frequent maintenance to prevent fire or explosion due to
accumulation of metallic dust. All personnel in the blast-
ing room should be provided with respiratory protection.
When ventilating confined spaces, all air replacing
that 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 engine
exhaust gases cannot be drawn into the ventilating sys-
tem. This precaution will also prevent exhaust gases
from 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 collectors
should be provided with blowout holes or relief panels.
Blowout panels should also be provided in ventilation
piping.
All fans, pipes, dust arrestors, and motors should be
grounded. Grounds should not be attached to pipes that
carry fuel gas or oxygen. Ventilating fans should be kept
running when cleaning out booths, pipes, etc. This pre-
vents the accumulation of dust or fumes in the system.
Aluminum and magnesium dusts present an explosive
hazard which requires special attention. Adequate wet
collector systems should be used with either of these
metals. Care should be exercised, since these metallic
dusts may generate hydrogen gas in water. These systems
should 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 large
confined spaces, such as encountered in boilers and
tanks, 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 the
equipment has been thoroughly cleaned.
Not for Resale
 AWS C2.25/C2.25M:2002

General Note: Notice extensive safety equipment.

Figure A1—Arc Spraying 85/15 Zn/Al on the Interior of a

7-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.

15
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Copyright American Welding Society

Provided by IHS under license with AWS
No reproduction or networking permitted without license from I HS Not for Resale
 --``,``-`-`,,`,,`,`,,`---

Copyright American Welding Society

Provided by IHS under license with AWS
No reproduction or networking permitted without license from I HS Not for Resale

Annex B
Guidelines for Preparation of Technical Inquiries
for AWS Technical Committees
(This guide is not a part of AWS C2.25/C2.25M:2002, Specification for Solid and Composite Wires and Ceramic
Rods for Thermal Spraying, but is included for information purposes only.)
B1. Introduction
The AWS Board of Directors has adopted a policy
whereby all official interpretations of AWS standards
will be handled in a formal manner. Under that policy, all
interpretations are made by the committee that is respon-
sible for the standard. Official communication concern-
ing an interpretation is through the AWS staff member
who works with that committee. The policy requires that
all requests for an interpretation be submitted in writing.
Such requests will be handled as expeditiously as possi-
ble but due to the complexity of the work and the proce-
dures
requirethat must be followed,
considerable time. some interpretations may
B2. Procedure
All inquiries must be directed to:
Managing Director, Technical Services
American Welding Society
550 N.W. LeJeune Road
Miami, FL 33126
All inquiries must contain the name, address, and af-
filiation of the inquirer, and they must provide enough in-
formation for the committee to fully understand the point
of concern in the inquiry. Where that point is not clearly
defined, the inquiry will be returned for clarification. For
efficient handling, all inquiries should be typewritten and
should also be in the format used here.
B2.1 Scope. Each inquiry must address one single pro-
vision of the standard, unless the point of the inquiry
involves two or more interrelated provisions. That provi-
sion must be identified in the scope of the inquiry, along
17
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from I HS Not for Resale
AWS C2.25/C2.25M:2002
with the edition of the standard that contains the provi-
sions or that the Inquirer is addressing.
B2.2 Purpose of the Inquiry.The purpose of the inquiry
must be stated in this portion of the inquiry. The purpose
can be either to obtain an interpretation of a standard re-
quirement, or to request the revision of a particular provi-
sion in the standard.
B2.3 Content of the Inquiry.The inquiry should be
concise, yet complete, to enable the committee to quickly
and fully understand the point of the inquiry. Sketches
should be used when appropriate and all paragraphs, fig-
ures, and tables (or the Annex), which bear on the in-
quiry must be cited. If the point of the inquiry is to obtain
a revision of the standard, the inquiry must provide tech- -
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nical justification for that revision.
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B2.4 Proposed Reply.The inquirer should, as a pro- `
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posed reply, state an interpretation of the provision that is
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the point of the inquiry, or the wording for a proposed re-
vision, if that is what the inquirer seeks.
B3. Interpretation of Provisions of
the Standard
Interpretations of provisions of the standard are made
by the relevant AWS Technical Committee. The secre-
tary of the committee refers all inquiries to the chairman
of the particular subcommittee that has jurisdiction over
the portion of the standard addressed by the inquiry. The
subcommittee reviews the inquiry and the proposed reply
to determine what the response to the inquiry should be.
Following the subcommittee’s development of the re-
sponse, the inquiry and the response are presented to the
entire committee for review and approval. Upon approval
 AWS C2.25/C2.25M:2002

by the committee, the interpretation will be an official in- only through a written request. The Headquarters staff
terpretation of the Society, and the secretary will transmit cannot provide consulting services. The staff can, how-
the response to the inquirer and to the Welding Journal ever, refer a caller to any of those consultants whose
for publication. names are on file at AWS Headquarters.

B4. Publication of Interpretations

B6. The AWS Technical Committee
All official interpretations will appear in the Welding
Journal. The activities of AWS Technical Committees in regard
to interpretations, are limited strictly to the Interpretation
of provisions of standards prepared by the committee or
to consideration of revisions to existing provisions on the
B5. Telephone Inq uiries
basis of new data or technology. Neither the committee -

Telephone inquiries to AWS Headquarters concerning nor the staff is in a position to offer interpretive or con- -
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AWS standards should be limited to questions of a gen- sulting services on: (1) specific engineering problems, or
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eral nature or to matters directly related to the use of the (2) requirements of standards applied to fabrications out- `
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standard. The Board of Directors’ policy requires that all side the scope of the document or points not specifically `
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AWS staff members respond to a telephone request for covered by the standard. In such cases, the inquirer
an official interpretation of any AWS standard with the should seek assistance from a competent engineer experi-
information that such an interpretation can be obtained enced in the particular field of interest.

18
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from I HS Not for Resale