The purpose of this Defence Standard is to provide designers and
users with advice on the application of flame sprayed coatings,
principally for wearing surfaces. It includes cleaning, preparation
of surfaces, design considerations, metals to be applied, quality
control, inspection, and testing.
It is not intended to apply to aerospace parts and
This Defence Standard is divided into three parts:
Part 1, Unfused metal coatings
Part 2, Fused metal coatings
Part 3, Ceramic and cermet coatings.
Part 1, Unfused metal coatings, deals with the use of flame
sprayed metal coatings to recover worn or mis-machined components
with similar or dissimilar metals, to provide wear resistance,
including hard facing, and to provide resistance to high and low
temperaturs corrosion. The process also covers the application of
metals to either metallic or various non-metallic surfaces for the
purposes outlined above, and it embraces coatings for electrical
purposes such as conductivity, screening, etc.
By way of example, the following are typical applications:
(1) Crankshafts and various types of rotating and reciprocating
shafts sprayed for wear and/or corrosion resistance with such
metals as carbon steel, stainless steel, chromium and other alloy
steels, molybdenum, etc.
(2) Hydraulic rams, etc, sprayed for wear and/or corrosion
resistance with such metals as carbon steel, stainless steel,
bronzes, aluminium bronze, etc.
(3) Mating surfaces of components such as ball races, flywheels,
etc, which are assembled using either shrink or interference fits,
sprayed with carbon steel, stainless steel, molybdenum, etc.
(4) Roll faces for wear and/or corrosion resistance sprayed with
carbon steel, stainless steel, bronzes, aluminium, etc.
(5) Exhaust pipes, silencers, hot gas ducts, chimneys, and
burners sprayed with aluminium, to a thickness of approximately
0.18 mm, to provide high temperature corrosion resistance up to
(6) Exhaust manifolds, furnace chairs, and furnace mechanical
handling parts sprayed with aluminium, to a thickness of
approximately 0.18 mm, sealed and heat-treated to provide high
temperature corrosion resistance up to 950ºC.
(7) Furnace boxes and covers sprayed with nickel-chromium with
an aluminium overlayer, to a thickness of approfimately 0.38 mm, to
provide high temperature corrosion resistance up to 1100ºC.
(8) For electrical conductivity, wood sprayed with copper for
transformer stray current collector rings, plastics sprayed
with copper for printed wiring boards, graphite sprayed with copper
for furnace electrodes. Thickness of deposit varies according to
(9) For electrical screening, radio valves and the walls,
floors, and ceilings of radio transmitter rooms and hospital
operating theatres sprayed with copper. Thickness of deposit varies
according to application.
This Standard must not be taken as approval to apply any flame
sprayed coating to a component without the written consent of the
purchaser or owner. This written consent may be in the form of a
contract or order, or may be in the form of written permission from
the Design/Approval Authority concerned.
If this Standard should be found unsuitable for a particular
requirement the Director of Standardization shall be informed of