Zn-Al 95/5 Spray Wire 4.8 mm

Understanding Zn-Al 95/5 Alloy Wire

Zn-Al 95/5 is a widely specified pseudo-alloy for thermal spray applications where galvanic protection and extended service life are critical. The 5% Aluminum addition refines the coating microstructure, improves adhesion, and provides a harder, more durable surface than pure zinc. This makes it ideal for cathodic protection of steel in marine, industrial, and high-humidity atmospheres. The 4.8 mm (3/16 inch) diameter is a standard size compatible with most high-output arc spray guns and larger flame spray setups, offering a good balance between feedability and deposition rate.

Key Features and Benefits

• Enhanced Corrosion Resistance: The Zn-Al 95/5 alloy provides active cathodic protection, sacrificing itself to protect the steel substrate even if the coating is scratched or damaged.
• Versatile Process Compatibility: Formulated for consistent feeding and melting in both electric arc spray and combustion flame spray systems. We confirm the optimal process fit on enquiry to match your specific gun model.
• Practical Pack Options: Available on 15 kg, 20 kg, and 25 kg spools, as well as coil packs, to suit different production volumes and minimize downtime during changeovers.
• Dense, Uniform Coatings: Produces a smooth, low-porosity coating that can be used as a final layer or as an excellent primer for paint systems (duplex coating).

Applications

This Zn-Al 95/5 wire is used across heavy industry and infrastructure for long-term asset protection. Common applications include:

• Steel Bridge Coatings: Protecting structural steel beams, girders, and trusses from atmospheric corrosion.
• Wind Turbine Towers: Providing a durable base coat on tower sections, both internally and externally.
• Water and Storage Tanks: Coating tank exteriors and interiors (where potable water approval is not required) for extended service life.
• Ductile Iron Pipes and Fittings: Applying a sacrificial zinc-aluminum layer to buried or exposed pipework.
• Marine and Offshore Structures: Protecting docks, locks, gates, and offshore platform components from saltwater spray and immersion.
• General Steel Fabrications: Used by job shops for OEM components requiring a specified anti-corrosion finish.

Selection and Handling Tips

For best results, ensure your spray gun's drive rolls and guides are correctly set for 4.8 mm soft wire. Store spools in a dry, covered area to prevent white rust formation on the wire surface before spraying. If you are switching from a different alloy or diameter, we recommend running a short test coupon to optimize your voltage, amperage, and standoff distance. Our team can provide technical guidance on starting parameters for common arc spray systems.

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

SPA2Z is a focused supplier of industrial surface preparation and coating consumables, connecting contractors and manufacturers with the materials they need to protect critical assets. For buyers of Zn-Al 95/5 Spray Wire 4.8 mm, we simplify procurement by offering clear pack options, responsive technical support, and a straightforward quotation process. We understand that consistent wire quality and reliable supply are essential to your coating operations.

When you enquire with SPA2Z, you get practical, product-specific assistance—not a generic sales pitch. We help you confirm the right alloy grade and diameter for your project, verify compatibility with your existing spray equipment, and provide a competitive price for your required volume. Whether you need a single spool for a trial or scheduled bulk deliveries for ongoing contract work, we are ready to support your thermal spray requirements.