Aws c2.25 2002 Thermal Spray Feedstock.pdf

8/11/2019 Aws c2.25 2002 Thermal Spray Feedstock.pdf

1/27

Specification for

Thermal Spray

FeedstockSolid

and Composite

Wire and Ceramic

Rods

AWS C2.25/C2.25M:2002

An American National Standard

yright American Welding Societyded by IHS under license with AWS

Not for Resaleeproduction or networking permitted without license from I HS


2/27

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

AWS C2.25/C2.25M:2002An American National Standard

Approved byAmerican 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.

Key WordsThermal spray, feedstock, ferrous,nonferrous, ceramic rod, chemical

composition, solid and composite

wires



--``,

``-`-`,,

`,,

`,

`,,

`---


3/27

Statement on Use of AWS American National Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American

Welding Society are voluntary consensus standards that have been developed in accordance with the rules of the American

National Standards Institute. When AWS standards are either incorporated in, or made part of, documents that are

included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry

the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the

governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all

cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards.Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by

agreement between the contracting parties.

International Standard Book Number: 0-87171-656-9

American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126

2002 by American Welding Society. All rights reserved

Printed in the United States of America

AWS American National Standards are developed through a consensus standards development process that brings

together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process

and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or

verify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether spe-cial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this

standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on

behalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someone

else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice

of a competent professional in determining the exercise of reasonable care in any given circumstances.

This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.

Publication of this standard does not authorize infringement of any patent. AWS disclaims liability for the infringement

of any patent resulting from the use or reliance on this standard.

Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

On occasion, text, tables, or figures are printed incorrectly (errata). Such errata, when discovered, are shown on theAmerican Welding Society web page (www.aws.org) under Technicalin the Departments column.

Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in writ-

ing, to the Managing Director Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126

(see Annex B). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may

be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. These

individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpre-

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 Committees 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.

Photocopy Rights

Authorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, or

educational classroom use only of specific clients, is granted by the American Welding Society (AWS) provided that the

appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400;

online: http://www.copyright.com.



--``,

``-`-`,,

`,,

`,

`,,

`---


4/27

iii

Personnel

AWS C2 Committee on Thermal Spray

E. Rybicki, Chair The University of Tulsa

T. Call, 1stVice 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 DivisionR. 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



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


5/27

iv

AWS C2J Subcommittee on Surfacing Materials for Thermal Spraying

J. B. C. Wu, Chair Deloro Stellite Co., Inc.

R. A. Sulit, Vice Chair Sulit Engineering

E. F. Mitchell, Secretary American Welding Society

C. Arata Anval Inc.

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



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


6/27

v

Foreword

(This Foreword is not a part of AWS C2.25/C2.25M:2002, Specification for Thermal Spray FeedstockSolid 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.



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


7/27



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


8/27

vii

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

5. Certification...........................................................................................................................................................2

6. Test Methods and Retest ......................................................................................................................................2

6.1 Chemical Analysis ........................................................................................................................................2

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 AGuide to Ventilation and Personnel Protection During Thermal Spraying ...............................................13

Annex BTechnical Inquiries ....................................................................................................................................17



--`

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


9/27

viii

List of Tables

Table Page No.

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

4 Chemical Composition Requirements for Thermal Spray Ceramic Rods .....................................................7

5 Standard Sizes for Thermal Spray Wires .......................................................................................................9

6 Standard Sizes for Thermal Spray Ceramic Rods..........................................................................................9

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

List of Figures

Figure Page No.

1 Thermal Spray Feedstock Classification System Format ..............................................................................8

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



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


10/27

AWS C2.25/C2.25M:2002

1

1. Scope

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 thescope 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 areshown within brackets [ ] or in appropriate columns in

tables and figures.

2. Reference Documents

The following ASTM1standards 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 Analysisof 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.

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

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


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 WeldingSize

Requirements

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.

Specification for Thermal Spray FeedstockSolid and Composite Wire and Ceramic Rods



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


11/27

AWS C2.25/C2.25M:2002

2

This specification may be used to classify and procure

solid and composite wire and ceramic rods for thermal

spraying.

4. Basis of Classification

4.1The thermal-spray solid and composite wires, and ce-

ramic rods in this specification are classified using a sys-

tem that is independent of U.S. Customary Units and the

International System of Units (SI). The classification is

according to chemical composition of the thermal-spray

material as specified in Tables 1 through 4. Table 1 lists

the chemical composition of solid ferrous wires. Table 2

lists the chemical composition of solid nonferrous wires.

Table 3 lists the chemical composition of the mixture of

the sheath and core material of composite wires. Table 4

lists the chemical composition of ceramic rods.

4.2 The system for classifying the thermal-spray feed-

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

as the prefix designation for solid-alloy and solid-composite wires, cored-composite wires, and ceramic

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

5.1The act of placing the C2.25 specification and classi-

fication designations on the packaging enclosing the

product, or the classification on the product itself, consti-

tutes the suppliers (manufacturers) certification that the

product meets all of the requirements of the specification.

5.2The 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 havebeen conducted. The basis for the certification required

by the specification is the classification test of represen-

tative material cited above, and the Manufacturers

Quality Assurance Program.

5.3For the purpose of determining conformance with this

specification, an observed or calculated value shall be

rounded to the nearest unit in the right-hand place figures

used in expressing the limiting values for quantities in ac-

cordance with the round-off method given in ASTM E 29,

Standard practice for Using Significant Digits in Test

Data to Determine Conformance with this Specification.

6. Test Methods and Retest

6.1 Chemical Analysis6.1.1The chemical compositions of ferrous and non-

ferrous solid and composite wire and ceramic rod feed-

stock are defined in Tables 1, 2, 3, and 4. The chemical

composition shall be determined by emission spectro-

chemical analysis, inductively coupled plasma spectros-

copy, and wet chemical analysis, singly or in

combination, in accordance with one or more of the fol-

lowing standards, or as agreed to by the purchaser and

supplier:


of Aluminum and Aluminum Alloys(referee)

(2) ASTM E 227, Standard Method for Optical Emis-

sion Spectrometric Analysis of Aluminum and Aluminum

Alloys by the Point-to-Plane Technique


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.

6.1.3The sample shall be analyzed by accepted ana-

lytical methods. For elements not covered by the abovelisted test methods, the referee test method per ASTM

E 34, shall be used or as otherwise agreed upon between

the manufacturer and the purchaser.

6.2 Retest

6.2.1If the results of any test fail to meet the require-

ment, that test shall be repeated twice. The results of both

retests shall meet the requirements. Specimens for retest

may be taken from the original sample. For chemical



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

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


12/27

AWS C2.25/C2.25M:2002

3

Table1

ChemicalCompositionRequirementsforSolidFerrous

ThermalSprayWires

C2.25

Classification

UNS

Number(2)

Common

Name

Alloy

Composition,W

eightPercent(1)

C

Cr

Fe

Mn

Mo

Ni

P

Si

S

Others

Amount

W-FeC-1

W-FeC-2

W-FeC-3

W-FeC-4

W-FeC-5

G10090

H15220

G10200

G10750

G10800

C

arbon

S

teel(3)

1010

0.080.15

0.150.23

0.180.28

0.80

0.500.90

RemRemRemRemRem

0.200.60

1.01.5

0.300.60

0.70

0.400.90

0.045

0.045

0.040

0.045

0.35

0.10

0.050

0.050

0.030

0.050

W-FeCrMn

W-FeCrC

W-FeNiCr

T87515

T87510

T87520

A

lloy

S

teel(4)

1.01.00.10

1.62.0

1.351.65

1.02.0

RemRemRem

1.72.0

0.250.40

2.50

0.150.25

1.03.0

3.75.0

0.010

0.020

0.030

0.35(6)

0.50

0.35(6)

0.040

0.020

0.030

Ti

0.110.15

W-FeCrNi-1

W-FeCrNi-2

W-FeCrNi-3

W-FeCrNi-4

W-FeCrNi-5

W-FeCrNi-6

W-FeCrNi-7

W-FeCrNi-8

W-FeCrNi-9

S30481

S30280

S20281

S20280

S31680

S31683

S31681

S41683

S42080

S

tainless

S

teel(5)

304

202

316

316L

316LSi

420

0.080

0.120

0.150

0.060

0.080

0.030

0.030

0.030

0.300.40

1820

1719

1719

1719

1820

1820

1820

1214

1214

RemRemRemRemRemRemRemRemRem

2.00

1.50

7.510.0

7.09.0

1.02.5

1.02.5

1.02.5

1.00

0.60

2.03.0

2.03.0

2.03.0

8.011.0

7.09.0

4.06.0

4.06.0

1114

1114

1114

1

.00

0

.60

0.045

0.060

0.030

0.030

0.030

0.020

1.00

0.50

1.00

0.080

0.300.65

0.300.65

0.651.00

0.080

0.50

0.045

0.030

0.030

0.030

0.020

CuCuCu

0.75

0.75

0.75

Notes:

(1)Singlevaluesshownaremaxim

umpercentages.Rem=remainder,

(2)SAE/ASTMUnifiedNumberin

gSystemforMetalsandAlloys.

(3)Carbonsteelsnominallycontain