"Engineered Surfaces for Exceptional Performance"
"Engineered Surfaces for Exceptional Performance"

Flexicord is manufactured by coextrusion of a paste containing the powder material (metallic, ceramic or carbide) and organic skin. Flexicord is sprayed through a Flamespray pistol using Oxygen & Acetylene gases.Flexicord products deliver excellent resistance to thermal cycling, abrasion, corrosion and dielectric exposure.

 

Thermal spray Flexicord products are available in a range of metallic, ceramic and carbide formulations. Consult our MSSA technical specialists to assist in selecting the right coating for your specific needs.

Ceramic Series 

Flexicord Type Composition Coating
Hardness
ASTM G65
Volume Loss
Coating
Density
Coating
Porosity
Pore
Diameter
Coating
Roughness
CTE
Pure Alumina Thermal Spray Flexicord (Al2O3)    700-770 Hv300  117 mm3 3.6 g/cm3 (0.13 lb/in3)  8 -12%   8 -12 μm Ra 7 x 10-6/K at 1000°C (1832°F)
Black Corundum 15 Thermal Spray Flexicord (Al2O3 15% TiO2)     900 - 1000 Hv100  32 mm3 3.6 g/cm3 (0.13 lb/in3)  6 - 8%    7 - 9 μm Ra 7.5 x 10-6/K at 700°C (1292°F)
Black Corundum 50 Thermal Spray Flexicord (Al2O3 50% TiO2)    900 - 1000 Hv100  38 mm3 3.6 g/cm3 (0.13 lb/in3)  6 - 8%    7 - 9 μm Ra 7.5 x 10-6/K at 700°C (1292°F)
Black Body Thermal Spray Flexicord  Cr2O3 - 55.25%
 Al2O3 - 27.1%
 SiO2 - 11%
 TiO2 - 6.65% 
 710 - 920 Hv300   3.9 g/cm3 (0.13 lb/in3)  8 - 10%   5 - 10 μm

56 μm Rz

 
Blue Corundum Thermal Spray Flexicord (Al2O3 3% TiO2)      800 Hv300  55 mm3 3.5 g/cm3 (0.126lb/in3)  6 - 8 %    6 - 8 μm Ra 7.5 x 10-6/K at 700°C (1292°F)
Ti-Elite Thermal Spray Flexicord (Al2O3 13% TiO2)    1010 Hv200  51 mm3 3.6 g/cm3 (0.13lb/in3)  4 - 7 %    3 - 4 μm R 7.5 x 10-6/K at 700°C (1292°F)
Ti-Tex Thermal Spray Flexicord (Al2O3 40% TiO2)    950 Hv200  6 mm3 3.6 g/cm3 (0.13lb/in3)  3 - 6%    3 - 4 μm Ra 7.5 x 10-6/K at 700°C (1292°F)
Spinel Thermal Spray Flexicord (Al2O3 30% MgO)    730 Hv300  76 mm3  3 g/cm3 (0.10lb/in3)  10 - 17%    7 - 12 μm Ra 8.8 x 10-6/K at 980°C (1688°F) 
Magnesium Zirconate Thermal Spray Flexicord (ZrO2 20% MgO)     760 Hv300  162 mm3  4.9 g/cm3 (0.17lb/in3)  10 - 15%    10 - 15 μm Ra 10 x 10-6/K at 1000°C (1843°F)

Titania Thermal Spray Flexicord (TiO2) 

TiO100%  950 Hv300  21 mm3 4.1 g/cm3 (0.15 lb/in3)  3 - 4%   5 μ 4 - 8 μm Ra 8.5 x 10-6/K at 1000°C (1832°F)

 

Ceramic Supra Series

The Supra line of ceramic-based thermal spray Flexicord products to increase the life of components exposed to demanding process conditions. The Supra Flexicord line provides denser coatings with lower porosity, smoother finish  after spraying (lower Ra) and finer microstructure than other Flexicord products.

Supra Flexicord products are available in a range of coating formulations for optimized resistance to mechanical wear, corrosion, thermal shock & thermal cycling. These materials provide excellent diffusion & thermal barrier characteristics as well as electrical insulation properties.

Flexicord Type Composition Coating
Hardness
ASTM G65
Volume Loss
Coating
Density
Coating
Porosity
Pore
Diameter
Coating
Roughness
Resistivity AC Dielectric
Strength
Chromia Supra Thermal Spray Flexicord (Cr2O3) Cr2O3 – 99.2%
Other – max 0.8%
 935 Hv300  6 mm3 5.2 g/cm3 (0.187 lb/in3)  1%  ~5 µm   3 µm Ra    
Alumina Supra Thermal Spray Flexicord (Al2O3 Al2O3 – 99.7%
Other – max 0.3%
 680 Hv300  36 mm3 3.8 g/cm3 (0.137 lb/in3)  4 - 6%   ~2 – 12 µm  3 – 5 µm Ra 2.108 Ω/cm at 700°C (1292°F) 10 – 15 kV/mm
Spinel Supra Thermal Spray Flexicord (Al2O3 30% MgO)  Al2O3 – 70%
MgO – 30%
1000 Hv300   4 g/cm3 (0.144 lb/in3)  4 - 7%   ~5 – 10 µm  7 – 12 µm Ra    
AZ Supra Thermal Spray Flexicord (Al2O3 23% ZrO2) Al2O3 – 75%
ZrO2 – 23%
Other – 2%
500 – 600 Hv300    4.3 g/cm3 (0.155 lb/in3)  2 - 5%  ~5 µm  3 – 5 µm Ra    
ZirMag Supra Thermal Spray Flexicord (ZrO2 22% MgO)  Al2O3 – 78%
MgO – 22%
650 Hv300   5.2 g/cm3 (0.187 lb/in3)  1.8 - 4%  1 – 10 µm   5 – 7 µm Ra    
Iron Oxide Thermal Spray Flexicord (Fe3O4) Fe3O4 – 92%
SiO2 – 3%
Other – 5% 
810 Hv300   5.1 g/cm3 (0.182 lb/in3)  6 - 8%  5 – 20 µm   12 – 13 µm Ra    

 

Bond Coat Series

Some applications require a bond coat layer to improve adhesion of thermal spray coatings designed to increase the life of parts & equipment. For this reason, MSSA offer two thermal spray Flexicord materials engineered to improve bond strength between substrate & sprayed ceramic coatings. These Flexicords enhance the coatings’ resistance to corrosion & oxidation in high-temperature applications, thus providing maximum protection in demanding services.

Flexicord Type Composition Coating
Hardness
Coating
Density
Coating
Porosity
Coating
Oxidation
Coating
Roughness
Melting
Temperature
NiCrAlY Bond Coat Thermal Spray Flexicord Ni 67% Al 10%
Cr 22% Y 1%
250 – 350 Hv300 7.2 g/cm3 (0.26 lb/in3)  5%   ~20%  6 - 8 μm    1400°C (2552°F)
NiChrome Thermal Spray Flexicord (NiCr) Ni 80%
Cr 20%
280 Hv300 7.25g/cm3 (0.262 lb/in3  1 - 3%   5 – 10 µm  6 - 8 μm Ra  1400°C (2552°F)

  

RocDur Series

RocDur series of thermal spray Flexicord deliver high-quality, cost effective coatings for flame spray application, either as sprayed or as fused. Made of a nickel self-fluxing alloy, RocDur thermal spray Flexicord are available in a range of wear-resistant compositions with matrix hardness from 19 HRC to 62 HRC.  Whichever formula meets your specific needs for corrosions resistance, wear resistance or, RocDur thermal spray Flexicord offer excellent coating efficiency, enabling users to save time & money.

Flexicord Type Composition Coating
Hardness
ASTM G65 
Volume Loss
Coating
Density
Coating
Porosity
Pore
Diameter
Coating
Roughness
CTE Melting
Temperature
RocDur 44 Thermal Spray Flexicord  NiCrBSiFeC Matrix 38HRC +/- 2 
Carbides 370 Hv300 
  8.1 g/cm3 (0.29 lb/in3) 3 - 5% as sprayed   5 to 15 µm  5 µm Ra 14.1 x 10-6/K at 700°C (1292°F)  1060°C (1940°F)
RocDur 6728 Thermal Spray Flexicord WC – 28%
NiCrBSi – 72% 
Matrix 60HRC
Carbides 1300Hv300 
  10.1 g/cm3 (0.36 lb/in3 <1% as fused 1µm as fused  –212.5 µm Ra as sprayed
2 – 4 µm as fused
   1060°C (1940°F)
RocDur 6740 Thermal Spray Flexicord    WC – 40%
NiCrBSi – 60% 
Matrix 60HRC
Carbides 1300Hv300 
  10.1 g/cm3 (0.36 lb/in3 <1% as fused <1 µm as fused –212.5 µm Ra as sprayed
2 – 4 µm as fused
   1060°C (1940°F)
RocDur 6750 Thermal Spray Flexicord   WC – 50%
NiCrBSi – 50%
Nickel 60 HRC
Carbides 2000 Hv300
3.52 mm3 12 g/cm3 (0.43 lb/in3) <1% as fused <1 µm as fused 10 – 12 µm Ra as sprayed
0.25 – 0.4 µm as fused
  1060°C (1940°F)
RocDur NS 60 Thermal Spray Flexicord Al2O3 ~33%
Ni base ~67%
Matrix 60 HRC  6.7 mm3 5.8 g/cm3 (0.21 lb/in3          

  

Carbide Series

MSSA carbide series of thermal spray Flexicord materials produce high performance tungsten carbide or chromium carbide coatingss. These coatings provide resistance to abrasion, erosion, fretting & sliding wear comparable to those produced by costlier HVOF methods.

Compared to HVOF or plasma sprayed coatings, the carbide series Flexicord products yield coatings with less internal stress which permits thicker coatings & better resistance to thermal cycling. The coatings can be used as sprayed – with roughness values from 4 – 6.5 μm – or can be finished with diamond or AZ grinding.

Flexicord Type Composition Coating
Hardness
ASTM G65
Volume Loss
Coating
Density
Coating
Porosity
Pore
Diameter
Coating
Roughness
HardKarb 12 Co Thermal Spray Flexicord WC – 88%
Co – 12%
1050 – 1200 Hv300 1.8 mm3  13.7 g/cm3 (0.13 lb/in3)  3 - 7%  5 – 10 µm 4.5 - 6.5 µm Ra
HardKarb 15 HC Thermal Spray Flexicord WC – 85%
Ni – 10%
Cr – 2.75%
Mo – 2.75%
Fe – 1.15%
Co – 0.45%
1000 – 1100 Hv300 3.4 mm3 13.3 g/cm3 (0.48 lb/in3)  3 - 5%  5 – 15 µm 4.5 - 6.5 µm Ra
HardKarb CoCr Thermal Spray Flexicord  WC – 85%
Co – 10%
Cr – 4%
700 – 1250 Hv300 1.6 mm3 13.3 g/cm3 (0.48 lb/in3  3 - 4%   5 – 10 µm  4.5 - 6.5 µm Ra 
ChromKarb Thermal Spray Flexicord (Cr3C2 25% NiCr)   Cr3C2 – 75%
NiCr – 25% 
900 Hv300  8.9 mm3  7.1 g/cm3 (0.26 lb/in3  2 - 4%  5 – 10 µm 5.5 - 6 µm Ra 

 

Thremal Spray Flexicord - Special Alloy Series

MSSA offer thermal spray Flexicord products in two non-magnetic alloy formulations:

  • Corec 6 – a cobalt-based alloy that imparts coatings with excellent friction resistance as well as protection from corrosion & oxidation at high temperatures
  • RocDur 625 – a nickel-based alloy that provides coatings with excellent corrosion & oxidation resistance that are ideal for salt-water environments
Flexicord Type Composition Coating
Hardness
ASTM G65
Volume Loss
Coating
Density
Coating
Porosity
Pore
Diameter
Coating
Roughness
Corec 6 Thermal Spray Flexicord  Co Cr29 W4.5 C1.15 (ST6)  39 – 44 HRC 480 Hv300    8.46 g/cm3 (0.306 lb/in3  7 %    2 -15 μm   6 – 8 µm Ra as sprayed
RocDur 625 Thermal Spray Flexicord NiCrMoFe  340 Hv300  40 Mps (5800 psi) 8.4 g/cm3 (0.303 lb/in3  2 - 5%   5 – 10 µm 6 - 8 µm Ra 

  

If you would like more information, details, samples or a demonstration of the process, please call on 07 3823 1004, or contact us via email on our Contact Form.