Zn-Al 95/5 Spray Wire 2.3 mm

Zn-Al 95/5 Alloy Wire for Corrosion Protection

Zinc-Aluminum 95/5 alloy wire is a widely specified material in the thermal spray industry for active corrosion protection. The addition of 5% aluminum to the zinc matrix improves the coating's ductility, adhesion, and corrosion resistance, particularly in environments with chlorides or industrial pollutants. The resulting coating acts as a galvanic anode, sacrificing itself to protect the steel substrate from rust and degradation.

This wire is formulated to produce dense, well-bonded coatings with low oxide content when sprayed with properly adjusted parameters. It is suitable for use with standard arc spray and combustion flame spray systems. The 2.3 mm (approximately 0.09 inch) diameter is a common size that balances melt rate and deposit efficiency for many industrial setups.

Key Features and Benefits

• Proven Alloy Composition: The 95/5 Zn-Al ratio provides a well-established balance of galvanic protection and coating longevity, outperforming pure zinc in many corrosive atmospheres.
• Consistent Diameter: The 2.3 mm wire is manufactured to tight tolerances, ensuring smooth, uninterrupted feeding through spray equipment and a stable arc or flame.
• Versatile Application: Can be applied via arc spray or flame spray processes, offering flexibility for both shop-floor and on-site coating jobs.
• Practical Packaging: Available on 15 kg, 20 kg, and 25 kg spools, as well as coil packs, to suit different project scales and equipment types.

Industrial Applications

Zn-Al 95/5 coatings are specified across industries where steel structures are exposed to atmospheric corrosion. Common applications include:

• Bridge and Infrastructure Maintenance: Coating steel girders, support beams, and expansion joints to extend service life without frequent repainting.
• Wind Energy: Protecting wind turbine towers and foundation sections from the corrosive effects of weather, salt spray, and humidity.
• Marine and Offshore: Applying anti-corrosion layers on ship decks, hull components, and offshore platform structures exposed to aggressive marine environments.
• Steel Fabrication: Providing a shop-applied primer or final coating for structural steel, tanks, and piping before installation.

Selection and Handling Tips

To achieve optimal results, confirm that your thermal spray system is configured for 2.3 mm wire and that your drive rolls and contact tips are in good condition. The wire should be stored in a dry, covered area to prevent surface oxidation before use. While Zn-Al wire is less sensitive to moisture than pure zinc, keeping spools sealed until needed is a good practice. Always conduct a test spray on a sample plate to fine-tune voltage, amperage, and standoff distance for your specific equipment and desired coating thickness.

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

SPA2Z is a supplier of industrial surface preparation and coating equipment, and we understand the critical role that quality consumables play in your coating process. We supply Zn-Al 95/5 Spray Wire 2.3 mm to contractors, fabricators, and maintenance teams who need reliable materials for corrosion protection projects. Our focus is on providing you with a straightforward procurement path for this specific alloy and diameter.

When you contact us, we can provide a current quotation based on your required quantity and preferred packaging—whether you need a single spool for a trial or bulk packs for a major infrastructure project. We can also discuss your application to help confirm compatibility with your existing thermal spray setup. Let us help you keep your projects moving with a steady supply of coating wire.