1/02-11

2.9.1.6A
POWDERS
TECHNICAL, APPLICATION & SAFETY DATA

POWDER Ref No P325/32.

Nickel Chrome Boron Silicon Self Fluxing Alloy.

Process Suitability.
Plasma Thermal HVOF
Yes Yes Yes

Bond Coat Recommendations:

No Bond Coat Required if Fused.
See note on Page 4.

General Description:
Self Fluxing Alloy resistant to wear by fretting, cavitation and erosion at low and
high temperatures up to 1550°F.

May be applied to Iron, Steel and Nickel based alloys.

Following spraying the coating is ‘Fused’ to form a pore free homogeneous

structure.
Typical Applications:
Pumps.
Liners.
Plug Gauges.
Exhaust Valve Seats.
Extrusion dies.

Function of Coating - Resistant to:

Abrasive Grains - Low Temperature Fretting - Intended Motion
Abrasive Grains - High Temperature Cavitation
Hard Surfaces - Low Temperature Particle Erosion - Low Temperature
Hard Surfaces - High Temperature Particle Erosion - High Temperature

Typical Composition % Particle Size Range:

Chrome 17.0 -325 + 15 microns.
Iron 4.0 -45 + 15 microns
Silicon 4.0
Boron 3.5
Carbon 1.0
Nickel Bal

Specifications:
This Powder meets the following Specifications:
Rolls Royce Pratt & Whitney General Electric Other
N/A N/A N/A N/A

___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.9.1.6A
Customers and Metallisation Ltd. accept no responsibility arising from its use.
© Metallisation Limited
Page 1 of 8
 2.9.1.6A
POWDER Ref No P325/32.

Nickel Chrome Boron Silicon Self Fluxing Alloy.

COATING PROPERTIES
Property Thermal Plasma HVOF HVOF
Coating as Sprayed Similar Unfused Fused
Values
Microinches aa Fine # 300 - 400 300 - 400
Microns aa # 7.5 - 10 7.5 - 10
Coating as Fused
Microinches aa Smooth # N/A 150 - 200
Microns aa # N/A 3.75 - 5
Coating Machined
Microinches aa N/A # # #
Microns aa # # #
Coating Ground
Microinches aa 10 - 15 # 7 - 10 7 - 10
Microns aa 0.25 - 0.37 # 0.2 - 0.25 0.2 - 0.25
Coating Lapped
Microinches aa 1-3 # 2-3 2-3
Microns aa 0.025 - 0.07 # 0.05 - 0.08 0.05 - 0.08
Thickness Limitation
inches 0.015″ # 0.050″ 0.050″
mm 0.4 # 1.3 1.3
Finishing Allowance
inches 0.001″ # 0.001″ 0.001″
mm 0.025 # 0.025 0.025

Plastic Range Narrow # N/A #

Shrinkage during Fusing 12% # N/A 10%
Bond Strength Fused Metallurgical # 9000psi #
Porosity Pore free # <0.5% #
Macrohardness Rc 60 # # #
Microhardness N/A # # #
Coating Density: 6.8g/cc
Coating Structure: Homogeneous
Magnetic Properties: Non Magnetic
Electrical Resistivity: N/A
Coefficient of Thermal
Expansion:
Melting Point: 1875°F (1024°C)

Resistance to: Abrasion: Very Good

Corrosion: Similar to Stainless Steel.

Fusing:This operation may be carried out by any one of the following methods:
1. Torch Fusing using an Oxygen/ Acetylene flame.
2. Furnace Fusing.
3. Induction Fusing.

See Technical Bulletin 2.9.1.16. for further details and for suitability of
applying these coatings to various base materials.
___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.9.1.6A
Customers and Metallisation Ltd. accept no responsibility arising from its use.
© Metallisation Limited
Page 2 of 8
 2.9.1.6A

POWDER Ref No P325/32.

Nickel Chrome Boron Silicon Self Fluxing Alloy

FINISHING:

1. Machining: Not Recommended

2. Wet Grinding:
Wheels Surface Cylindrical Centreless
Silicon Carbide:
Roughing GC46 - H11 - VR GC60 - J11 - VR GC60 - J11 - VR
Finishing N/A N/A N/A
Diamond N/A N/A N/A

Speeds
Wheel SFPM 5500 - 6500 5500 - 6500 5500 - 6500
Wheel m/min 1650 - 1950 1650 - 1950 1650 - 1950

Roughing Finishing Roughing Finishing

Work SFPM N/A 70 100 70 100
Work m/min N/A 21 30 21 30

Roughing Finishing
Table Inches/Min 400 600 12 N/A
Table mm/sec 170 250 5 N/A

Roughing Finishing
Cross Feed 0.030 0.010 N/A N/A
inches
Cross feed mm 0.76 0.25 N/A N/A

Regulating Wheel:
Angle N/A N/A 2°
RPM N/A N/A 29

Notes:
1. The above is issued as a guide.
You may need to substitute alternative wheels, feeds and speeds to suit
local conditions or requirements.
2. To obtain finer finishes use finer grit wheels.
3. Do not glaze a coarse grit wheel to obtain a finer finish

Guide to Wheel Selection.

Softer Wheel Harder Wheel
Faster Stock Removal Finer Finish
Large Area of Contact Small Area of Contact
Light Pressure Heavy Pressure
Wide Wheels Narrow Wheels

___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.9.1.6A
Customers and Metallisation Ltd. accept no responsibility arising from its use.
© Metallisation Limited
Page 3 of 8
 2.9.1.6

POWDER Ref No P325/32.

Nickel Chrome Boron Silicon Self Fluxing Alloy.

OPERATING PARAMETERS PLASMA

A A/H2 N2/H2
GUN PS50
Nozzle
Powder Port

GAS - PRESSURE
Primary psi
Primary bar

Secondary - psi
Secondary - bar

GAS - FLOW
Primary
Secondary

POWER
Arc Amps
Arc Volts

POWDER FEED
Feed Screw
Feed Screw RPM
Carrier Gas

Gun Distance
inches
mm

Spray Rate
lb/hr
kg/hr

Notes:
1. The Plasma will produce a ‘Semi Fused’ coating.
If the coating is to be used in this condition a bond coat of P636/16 should
be used. If the coating is to be fused DO NOT USE A BOND COAT.

2. Component Preheat temperature should be 200°F - 250°F (90°C - 120°C)

Spraying temperature should not exceed 400°F (200°C)
___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.9.1.6A
Customers and Metallisation Ltd. accept no responsibility arising from its use.
© Metallisation Limited
Page 4 of 8
 2.9.1.6A

POWDER Ref No P325/32.

Nickel Chrome Boron Silicon Self Fluxing Alloy.

COSTING DATA PLASMA

A A/H2 N2/H2
Coverage Rate
sq ft/hr/0.001″
sq metre/hr/0.1mm

Powder Required
lb/sq ft/ 0.001″
kg/sq metre/0.1mm

Deposit Efficiency %
Deposit Rate
lb/hr
kg/hr

___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.9.1.6A
Customers and Metallisation Ltd. accept no responsibility arising from its use.
© Metallisation Limited
Page 5 of 8
 2.9.1.6A
POWDER Ref No P325/32.

Nickel Chrome Boron Silicon Self Fluxing Alloy.

SPRAYING PARAMETERS
THERMAL SPRAY

GUN
Nozzle
Mixing Chamber
Air Cap
Powder Valve
Air Jet Pressure psi
Air Jet Pressure bar
Air Jet Intersection inches
Air Jet Intersection mm

Vibrator
Spay Distance inches
Spay Distance mm

Gases Pressure Flow

psi bar
Oxygen
Acetylene
Hydrogen

Costing Data
lb/hour kg/hour
Spray Rate

cu ft/hour cu metre/hour
Gas Consumption
Oxygen
Acetylene
Hydrogen

sq ft/hour/0.001″ sq metre/hour/0.1mm
Coverage Rate

lb/sq ft/0.001″ kg/sq metre/0.1mm

Powder Required

Deposit Efficiency %

Note: Component Preheat temperature should be 200°F - 250°F (90°C - 120°C)

Spraying temperature should not exceed 400°F (200°C)

___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.9.1.6A
Customers and Metallisation Ltd. accept no responsibility arising from its use.
© Metallisation Limited
Page 6 of 8
 2.9.1.6A

POWDER Ref No P325/32.

Nickel Chrome Boron Silicon Self Fluxing Alloy.

GENERAL NOTES

1. Surface Preparation:

Pressure Suction
Blast Media psi bar psi bar Thermal Plasma HVOF
Aluminium Oxide Coarse 30 2.04 90 6.1 No No N/A
Aluminium Oxide Medium 30 2.04 90 6.1 No No N/A
Aluminium Oxide Fine 30 2.04 90 6.1 No No N/A
Angular Chilled Iron Grit 90 6.1 N/A N/A Yes Yes N/A
G24/G34

1.1 Aluminium Oxide is generally used to prepare:

1.1.1. Hardened surfaces.

1.1.2. Soft substrates, such as Aluminium.
1.1.3. Titanium and Titanium Alloys.
1.1.4. Surfaces which require thin coatings up to 0.020″

1.2. Angular Chilled Iron Grit is generally used to prepare:

1.2.1. Unhardened surfaces.

1.2.2. Preparation for ‘Self Fluxing Alloys’ i.e. Fused coatings.
1.2.3. Surfaces which require thick coatings in excess of 0.020″

2. Notes:

2.1. Aluminium Oxide breaks down readily, ensure that new grit is
continually added to maintain good quality.
2.2. Ensure that blasting media is free from contamination.
2.3. Components should be ‘air washed’ after blasting to remove dust
and debris.

3. Sealing:

Not Required.

___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.9.1.6A
Customers and Metallisation Ltd. accept no responsibility arising from its use.
© Metallisation Limited
Page 7 of 8
 2.9.1.6A

POWDER Ref No P325/32.

Nickel Chrome Boron Silicon Self Fluxing Alloy.

HEALTH & SAFETY

HAZARDS:

To comply with Health and Safety Legislation you are recommended to consult the
COSH Data Sheet referrng to this material.

SAFETY MEASURES:

1. Thermal Spraying should be carried out in accordance with the

manufactures instructions and the parameters laid down for the process.

2. Supervisory staff and operators should be familiar with the Metallisation

Handbook applicable to the equipment being used.

3. Extraction equipment meeting the local Health & Safety requirements

should be installed.

4. Where necessary operators & observers may also require the use of the
following:
Ear Defenders
Eye Protection
Protective Clothing
Respiratory Equipment
Gloves

5. Refer to the Health & Safety Data Sheet applicable to the material being
used.

6. DISREGARDING THESE INSTRUCTIONS MAY BE HAZARDOUS TO

YOUR HEALTH

Notes:

1. The Spray Parameters quoted produce good, economic

coatings and should be used as a starting point.
2. For specific applications, it may be necessary to change
parameters to provide particular coating qualities
3. A deviation from the parameters may change
characteristics such as: Hardness
Porosity
Deposit Efficiency
Bond Strength

___________________________________________________________________
The information contained in this Technical Bulletin is offered as a guide to T.B. 2.9.1.6A
Customers and Metallisation Ltd. accept no responsibility arising from its use.
© Metallisation Limited
Page 8 of 8