Zn-Al 95/5 Spray Wire 2.0 mm

Alloy Composition and Coating Performance

The 95/5 Zinc-Aluminum alloy is a widely specified coating material for corrosion control. The high zinc content ensures active cathodic protection, sacrificing itself to protect the steel substrate even if the coating is scratched or damaged. The addition of 5% aluminum enhances the coating's hardness and provides a stable oxide layer, which slows down the consumption rate of the zinc and extends the coating's life compared to pure zinc wires in many environments.

This wire is commonly used to protect steel in bridges, infrastructure, marine components, and industrial equipment. The resulting coating is ductile, adheres well to properly prepared surfaces, and serves as an excellent primer for paint systems, creating a synergistic duplex coating system for maximum longevity.

Application and Process Guidance

For optimal results, the steel substrate should be prepared to a near-white metal blast cleaning standard (Sa 2.5 / NACE No. 2) with a sharp angular profile. The 2.0 mm diameter is a common size that provides a good balance between deposition rate and coating smoothness in both arc and flame spray systems. Spray parameters such as voltage, amperage, stand-off distance, and atomizing air pressure must be optimized for your specific gun model to achieve a dense, well-bonded coating.

We recommend a pull-test or bend test on a sample coupon to validate your process parameters before starting full-scale production. Our technical team can assist with general application guidelines and help you select the correct wire grade for your service environment.

About SPA2Z — Your Source for Zn-Al 95/5 Spray Wire

SPA2Z supports industrial surface preparation and coating applicators by supplying Zn-Al 95/5 Spray Wire in 2.0 mm diameter. We understand that consistent wire quality, cast, and helix are critical for uninterrupted spray operations. Our focus is on providing reliable coating wires that help you achieve specified coating thicknesses and bond strengths without wire feed issues.

We offer flexible pack options to match your consumption rate, from standard 15 kg spools for smaller jobs to 25 kg spools or coil packs for high-volume production. Whether you are a job shop exploring thermal spray for the first time or a large-scale applicator managing multiple systems, we can help you with wire selection, process compatibility checks, and competitive supply. Request a quote today, and let us know your required diameter, pack size, and estimated monthly volume so we can prepare a tailored offer.