Issued October 2000

Supersedes January 1997

TM

®
Metcoloy #5
Austenitic Stainless
Steel Wire

Technical Bulletin #10-627

 ®
Metcoloy #5 Austenitic Stainless Steel Wire
For Electric Arc Spraying
Metcoloy #5 is an austenitic low carbon 202 Type Stainless Steel wire manufactured exclusively for
wire arc and flame spraying. Compared to Metcoloy #1, Metcoloy #5 coatings offer lower shrink and
better machinability properties while still offering high aqueous corrosion resistance. In addition,
Metcoloy #5 coatings offer good wear qualities and high strength and are recommended for use on
parts where coating shrink may be a problem.

Metcoloy #5 is used successfully on machine elements such as seal rings, gland castings, valve
plugs, low pressure stationary blading and packing sections.

Table of Contents

Applications page 2

Typical Wire Properties page 3

Typical Coating Characteristics – SmartArcTM (200 amps) page 3

Coating PhotoMicrographs – SmartArc (200 amps) (100x) page 4

Recommended Finishing Procedures page 5

Safety Recommendations page 5

Storage Requirements page 5

Recommended Parameters – SmartArc (200 amps) page 5

Applications

Metcoloy #5 coatings are ideal candidates for use in the following industries:

• Aircraft/ Aerospace • Industrial Transportation

• Chemical Processing • Petrochemical (including Natural Gas)
• Electrical Equipment • Steel Mills
(Home/ Industrial) • Marine

Metcoloy #5 conforms to Department of Defense specification MIL-W-6712, Table I, Stainless Steel, 18 - 5.

#10-627 Metcoloy #5 Austenitic Stainless Steel Wire 2

Typical Wire Properties

Typical chemical composition (weight %) of Metcoloy #5 is as follows:

Iron: Balance Silicon: 1.0

Chromium: 18.0 Carbon: 0.15
Manganese 8.5 Phosphorous: 0.06
Nickel: 5.0 Sulfur: 0.03

Wire diameter size available: 14 Ga. (1.63 mm, 0.064”)

Typical Coating Characteristics – SmartArc (200 amps)

Air Cap: Fine Fine Fan Hi-Velocity

Primary Air Pressure, psi: 35 60 35 35

Secondary Air Pressure, psi: 0 0 25 0

Surface Profile:
As-Sprayed,
micrometers Ra: 11 - 14 10 - 13 10 - 14 9 - 11
microinches aa: 450 - 550 400 - 500 400 - 550 350 - 450
Machined,
micrometers Ra: <2.2 <2.2 <2.2 <2.2
microinches aa: <85 <85 < 85 <85
Ground, (80 grit SiC)
micrometers Ra: <0.15 <0.15 <0.15 <0.15
microinches aa: <6 <6 <6 <6

Hardness:
Superficial hardness, Rc: 19 - 21 30 - 35 20 - 25 20 - 25
Microhardness, HV0.3: 250 - 350 375 - 500 300 - 400 325 - 425

Bond Strength (ASTM C-633)1:

“C” Grit Blasted Steel,
MPa: 58.1 58.1 58.1 58.1
Psi: 8,500 8,500 8,500 8,500

Density g/cm3: 6.5 6.5 6.5 6.5

Coating Thickness Limits:

“C” Grit Blasted Steel,
mm: 1.0 1.0 1.0 1.0
0.001 inches: 40 40 40 40

#10-627 Metcoloy #5 Austenitic Stainless Steel Wire 3

 Typical Coating Characteristics – SmartArc (200 amps) (cont’d)

Coating Weight:
kg/m2/0.1mm: 0.65 0.65 0.65 0.65
lb/ft2/0.001”: 0.03 0.03 0.03 0.03

Bond strength measured using Master Bond EP15 epoxy from Master Bond, Inc., Hackensack, NJ.
1

Results may vary depending on the curing process and type of epoxy used to perform the bond test.

Coating PhotoMicrographs – SmartArc (200 amps) (x100)

100µm 100µm

Fig. 1 - SmartArc sprayed Metcoloy #5 with Fine Fig. 2 - SmartArc sprayed Metcoloy #5 with Fine Air
Air Cap at 2.4 bar (35 psi). Cap at 4.1 bar (60 psi) produces higher hardness.

100µm 100µm

Fig. 3 - Metcoloy #5 coatings sprayed with the Fig. 4 - SmartArc sprayed Metcoloy #5 with High
Fan Air Cap at 2.4 bar (35 psi) (primary) and 1.7 Velocity Air Cap at 2.4 bar (35 psi).
bar (25 psi) (secondary) air pressure offer wider
spray patterns.

#10-627 Metcoloy #5 Austenitic Stainless Steel Wire 4

Recommended Finishing Procedures

The recommended machining parameters for optimal coating finish are as follows:

Tool Bit: Kennametal K6 or equivalent

Work Speed: 30-38 m/min. (100 - 125 SFPM)
Traverse Rate: 0.076 mm/rev. (0.003 in./rev.)
Infeed: 0.076 mm/rev. (0.003 in./rev.)
Lubricant: dry

Safety Recommendations

The Material Safety Data Sheet (MSDS) for Metcoloy #5 is available upon request. If personnel must
be in the spray environment during spray operations, protective clothing, respirators, safety eyeglasses
and ear protection must be worn. The spray area must always be equipped with suitable exhaust and
dust collection systems.

Storage Requirements

Wires should be stored in a clean, dry area and preferably kept boxed in a carton.

Recommended Parameters – SmartArc (200 amps)

Air Cap: Fine Fan Hi-Velocity

Air Pressure:
Primary, bar: 2.4 - 4.1 2.4 2.4
psi: 35-60 35 35
Secondary, bar: 0 1.7 0
psi: 0 25 0

Operating Parameters:
Voltage, (V): 26 - 28 26 - 28 26 - 28
Amperage, (A): 200 200 200

Hourly Consumption:
kg. Wire: 9.1 9.1 9.1
lbs. Wire 20 20 20

Spray Distance:
mm: 102 - 152 102 - 152 102 - 152
inches: 4-6 4-6 4-6

Wire Clamping Pressure:

bar: 1.7 - 2.4 1.7 - 2.4 1.7 - 2.4
psi: 25 - 35 25 - 35 25 - 35

#10-627 Metcoloy #5 Austenitic Stainless Steel Wire 5

Recommended Parameters – SmartArc (200 amps) (cont’d)

Front Roller Type: Serrated Serrated Serrated

Deposit Efficiency, %: 75 75 75

Wire Required:
kg/m2/0.1mm: 0.866 0.866 0.866
lb/ft2/0.001”: 0.045 0.045 0.045

Coverage:
m2/hr/0.1mm 10.48 10.48 10.48
ft2/hr/0.001”: 443.52 443.52 443.52

The information provided in this document is for the convenience of Sulzer Metco’s 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.

#10-627 Metcoloy #5 Austenitic Stainless Steel Wire 6