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

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Flexicord is manufactured by co-extrusion of a paste containing the powder material (metallic, ceramic or carbide) and organic skin. It is sprayed through a Flame Spray pistol using Oxygen & Acetylene gases. Flexicord products deliver excellent resistance to thermal cycling, abrasion, corrosion and dielectric exposure. When compared with HVOF and Plasma sprayed coatings, Flexicord consumables impart coatings with less internal stress, allowing thicker coatings with better thermal cycling resistance & wear protection.

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.

Spray and Fuse with Flexicord ROCDUR Series for Hard-Facing

Application Examples

Rewinder Rollers - Saint-Gobain Coating Solutions

Aluminium Casting - Saint-Gobain Coating Solutions

Textile Equipment Coatings - Saint-Gobain Coating Solutions

Metal Wire Drawing - Saint-Gobain Coating Solutions


Ceramic Series

The ceramic-based thermal spray Flexicord products are used to increase the life of components exposed to demanding process conditions. Ceramic Flexicord products are available in a range of coating formulations to cover a wide range of applications including resistance to mechanical wear, corrosion, thermal insulation, electrical insulation, diffusion barrier.

Pure Alumina Thermal Spray Flexicord (Al2O3)

Features & Benefits

  • Corrosion resist in most acid & alkaline environments.
  • Suitable for high-temperature applications.
  • Good diffusion barrier coating for precious metals (platinum).
  • High thickness possible of up to 5 mm make crucibles and other components.
  • Low thermal conductivity -- 0.01 kcal/cm at 1000°C (1832°F).
  • Bond strength – 25 MPa (625 psi).

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
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)

Features & Benefits

  • Good absorption & diffusion of infrared rays (IR).
  • Moderate corrosion resistance in acidic & alkaline environments.
  • Moderate abrasion resistance.
  • Suitable for hand-held spraying on large surfaces.
  • Slightly conductive.

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
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)

Features & Benefits

  • Good absorption & diffusion of infrared rays (IR).
  • Moderate corrosion resistance in acidic & alkaline environments.
  • Moderate abrasion resistance.
  • Suitable for hand-held spraying on large surfaces.
  • Slightly conductive coating properties.

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
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

Features & Benefits

  • Black Body ceramic coating for solar absorbers.
  • Coating can be easily applied on site.
  • High surface roughness: Rz =  56 μm (promotes absorptivity).
  • High Solar absorpitivity: 93.5%: promotes heat absorption.
  • Black color + absorptivity stable on 25 - 900°C (77 - 1652°F).
  • Low shrinkage: 0.75% between 25 - 900° (77 - 1652°F).

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
Cr2O - 55.25%
Al2O3  - 27.1%
SiO2  - 11%
TiO - 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

Features & Benefits

  • Good corrosion resistance in acidic & alkaline environments.
  • Moderate abrasion resistance.
  • Suitable for hand-held spraying on large surfaces.
  • Coating thickness over 1mm possible.

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
800 Hv300 55 mm3 3.5 g/cm3 (0.126 lb/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)

Features & Benefits

  • Excellent sliding wear resistance.
  • Excellent smooth finish after grinding – Ra from 0.2 – 0.4 μm.
  • Bond strength on NiCr – 57 MPa (8260 psi).
  • Moderate corrosion resistance – can be sealed to improve resistance.
  • Slightly conductive – ideal for textile applications.
  • Recommended for pump sleeves, bushings, rods, textile friction parts & mud pump shafts.

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
1010 Hv200 51 mm3 3.6 g/cm3 (0.13 lb/in3) 4 - 7% 3 - 4 μm Ra 7.5 x 10-6/K at 700°C (1292°F)

Ti-Tex Thermal Spray Flexicord (Al2O3 40% TiO2)

Features & Benefits

  • Excellent sliding wear resistance.
  • Excellent smooth finish after grinding – Ra from 0.2 – 0.4 μm.
  • Bond strength on NiCr – 57 MPa (8260 psi).
  • Moderate corrosion resistance – can be sealed to improve resistance.
  • Slightly conductive – ideal for textile applications.
  • Recommended for pump sleeves, bushings, rods, textile friction parts & mud pump shafts.

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
950 Hv200 6 mm3 3.6 g/cm3 (0.13 lb/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)

Features & Benefits

  • Suitable for contact with molten metals (Aluminum and Zinc).
  • Ideal thermal barrier coating for crucibles, chutes & fusion pots.
  • Lower wettability versus Aluminum and Zinc ideal coating for molds, chutes & funnels.

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
730 Hv300 76 mm3 3 g/cm3 (0.10 lb/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)

Features & Benefits

  • CTE of magnesium zirconate is close to the CTE of steel.
  • Provides protection against contact for molten steel for a short time.
  • Acts a bond coat for slurries on steel chutes and moulds.

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
760 Hv300 162 mm3 4.9 g/cm3 (0.17 lb/in3) 10 - 15% 10 - 15 μm Ra 10 x 10-6/K at 1000°C (1843°F)

Titania Thermal Spray Flexicord (TiO2)

Features & Benefits

  • Used as bond coat when Nickel formulations aren’t suitable.
  • Low AC dielectric strength – 4 KV/mm.
  • Low resistivity – approximately 2 x 104 Ω/cm at 700°C (1292°F).
  • Soluble in alkalis & sulfuric acid, but resistant to attack in many other environments.

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss  Coating Density Coating Porosity Pore Diameter Coating Roughness CTE
TiO- 100% 950 Hv300 21 mm3 4.1 g/cm3 (0.15 lb/in3) 3 - 4% 5 μm 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 micro-structure 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.

Chromia Supra Thermal Spray Flexicord (Cr2O3)

Features & Benefits

  • Produces dense, hard coatings.
  • Excellent corrosion resistance in acidic & alkaline environments.
  • Resistant to abrasion, fretting, cavitation and particle erosion.
  • Very good surface finishing as sprayed.

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss  Coating Density Coating Porosity Pore Diameter Coating Roughness
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)

Features & Benefits

  • Imparts dense coating for protection against friction & corrosion in most acidic & alkaline environments.
  • Ideal for high temperature and electrical insulation applications.
  • Diffusion barrier coating to protect metals from oxidation or carburation.

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss  Coating Density Coating Porosity Pore Diameter Coating Roughness Resistivity AC Dielectric Strength
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)

Features & Benefits

  • Good dielectric strength at high temperatures.
  • Good corrosion resistance.
  • Moderate abrasion resistance.
  • Good diffusion/thermal barrier coating.
  • Suitable for contact with molten metals (Aluminum and Zinc).

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
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)

Features & Benefits

  • Excellent abrasion resistance.
  • Good resistance against thermal shock & thermal cycling.
  • Good corrosion resistance in acidic environments.
  • Applicable to refractory steel up to 750°C (1382°F).

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
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)

Features & Benefits

  • Produces smooth, fine structured coatings.
  • Good resistance to thermal shock & thermal cycling.
  • Ideal for tools in contact with steel & steel extrusion dies.
  • Ideal for high temperature applications.

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
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)

Features & Benefits

  • CTE close to that of steel.
  • Suitable for delaminating layer in steel forging applications.
  • Good impact and scratch resistance.
  • Good corrosion resistance in acidic & alkaline environments.

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
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.

NiCrAlY Bond Coat Thermal Spray Flexicord

This nickel-based thermal spray Flexicord improves the adhesion of the coating to the substrate, thus enhancing the performance of ceramic coatings in demanding services. 

Features & Benefits

  • Improves bond strength of ceramic coatings – up to 36 MPa (5220 psi).
  • Enhances resistance to corrosion & oxidation in high temperature environments.
  • Ideal bond coat for zirconia & alumina coatings on steel, stainless steel & cast iron surfaces, particularly for high-temperature applications.

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Coating Oxidation Coating Roughness Melting Temp.
Ni 67% Al 10%
Cr 22% Y 1%
250 - 350 Hv300

7.2 g/cm3 (0.26 lb/in3)

5% ~20% 6 – 8 µm Ra 1400°C (2552°F)

NiChrome Thermal Spray Flexicord (NiCr)

This nickel-chromium thermal spray Flexicord improves the adhesion of the coating to the substrate, thus enhancing the performance of ceramic coatings in demanding services. 

Features & Benefits

  • Improves bond strength of ceramic coatings from 35 – 55 MPa (5000 – 8000 psi).
  • Good resistance to oxidation up to 1000°C (1832°F).
  • Ideally recommended for applications requiring very smooth finishes.

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness Melting Temp.
Ni 80%
Cr 20%
280 Hv300

7.25 g/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 corrosion resistance, wear resistance or, RocDur thermal spray Flexicord offer excellent coating efficiency, enabling users to save time & money. 

RocDur 44 Thermal Spray Flexicord

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

  • Self-fluxing nickel alloy.
  • Produces coating quality close to that of plasma spray/HVOF.
  • Very smooth coating with moderate hardness.
  • Good resistance to friction wear.
  • Easy to polish after spraying.

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness CTE Melting Temp.
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

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

  • Composite coating made of a nickel self-fluxing alloy with tungsten carbide particles.
  • Excellent resistance to abrasive & erosive wear.
  • Good corrosion resistance.
  • Ideal for non-slip surfaces such as rollers & capstans.

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness Melting Temp.
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

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

  • Composite coating made of a nickel self-fluxing alloy with tungsten carbide particles.
  • Excellent resistance to abrasive & erosive wear.
  • Good corrosion resistance.
  • Ideal for non-slip surfaces such as rollers & capstans.

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness Melting Temp.
WC – 40%
NiCrBSi – 60%
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 6750 Thermal Spray Flexicord

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

  • Composite coating made of a nickel self-fluxing alloy with tungsten carbide particles.
  • Excellent resistance to abrasion & erosion.
  • Good corrosion resistance.
  • Roughness of 6750 is greater than that of RocDur 6740.
  • Ideal for non-slip surfaces such as rollers & capstans (as sprayed).

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness Melting Temp.
WC – 50%
NiCrBSi – 50%
Nickel 60 HRC
Carbides 2000 Hv300

3.52 mm

12 g/cm3 (0.43 lb/in3)

<1% as fused <1µm 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

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

  • Exceptional hardness provides excellent wear resistance for a long-lasting, skid-resistant coating.
  • Unlike non-skid paints, NS 60 is not prone to flaking.
  • NS 60 is fire resistant, making it ideal for marine & offshore applications.

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Roughness (as sprayed)
Al2O3 ~33%
Ni base ~67%
Matrix 60 HRC

6.7 mm3

5.8 g/cm3 (0.21 lb/in3)

19 µm Ra
143 µm Rmax
73 µm RP
147 µm Rt

 


Carbide Series

MSSA carbide series of thermal spray Flexicord materials produce high performance tungsten carbide or chromium carbide coatings. 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.

HardKarb 12 Co Thermal Spray Flexicord

Features & Benefits

  • Produces hard, dense coatings.
  • Excellent resistance to abrasion, erosion, fretting & sliding wear.
  • Maximum temperature: 500°C (932°F).
  • Not suitable for severe corrosive or oxidizing environments.
  • Ideal coating for paper rolls, wire drawing equipment, fan & compressor blades, pump seals & housings.
  • Protects against coal dust, non-corrosive slurry & sand.

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness
WC – 88%
Co – 12%
1050 – 1200 Hv300

1.8 mm

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

Features & Benefits

  • Produces hard, dense coatings.
  • Excellent resistance to abrasion, erosion, fretting & sliding wear.
  • Excellent corrosion resistance in seawater, diluted mineral and hydrocarbon environments.
  • Not suitable for severe corrosive or oxidizing environments.
  • Ideal for marine environments, petrochemical & off-shore applications.

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness
WC – 85%
Ni – 10%
Cr – 2.75%
Mo – 2.75%
Fe – 1.15%
Co – 0.45%
1000 – 1100 Hv300

3.4 mm

13.3 g/cm3 (0.48 lb/in3)

3 - 5% 5 – 15 µm 4.5 - 6.5 µm Ra

HardKarb CoCr Thermal Spray Flexicord

Features & Benefits

  • Dense coating with excellent resistance to abrasion, erosion, cavitation & sliding wear.
  • Better corrosion & abrasion resistance than HardKarb 12 Co.
  • Ideal for wet corrosive environments & water-based solution applications.
  • Recommended for pump sleeves, bushings, mud pump shafts, paper rolls, gate & ball valves, hydraulic cylinders & compressor shafts.
  • Maximum temperature: 500°C (932°F).
  • Hard Chrome replacement.

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness
WC – 85%
Co – 10%
Cr – 4%
700 - 1250 Hv300

1.6 mm

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) 

Features & Benefits

  • Higher operating temperature than other HardKarb formula – up to 870°C (1598°F).
  • Suitable for aluminum substrates.
  • Dense coating with excellent oxidation, cavitation & erosion resistance.
  • Hot gas corrosion resistance, especially in sulfurous gases.
  • Can be sealed to improve corrosion resistance.
  • Recommended for hydraulic valves, fuel rod mandrels, tooling, machine parts, boiler tubes, WTE incinerators & hot forming dies.

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness
Cr3C2 – 75%
NiCr – 25%
900 Hv300

8.9 mm

7.1 g/cm3 (0.26 lb/in3)

2 - 4% 5 – 10 µm 5.5 - 6 µm Ra

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.

Corec 6 Thermal Spray Flexicord

Features & Benefits

  • Excellent friction wear resistance with moderate hardness.
  • Withstands many corrosive environments such as phosphoric acid & acetic acid.
  • Ideal for environments with a combination of abrasive & erosive wear along with corrosion/oxidation at high temperatures.

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
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

Features & Benefits

  • Recommended for oxidation resistance up to 1093°C  (2000°F).
  • Corrosion resistant in salt water.
  • Ideal for WTE boiler water jacket tube packages in combustion chambers & super heaters.

Physical Properties

Composition Coating Hardness Bond Strength Coating Density Coating Porosity Pore Diameter Coating Roughness
NiCrMoFe 340 Hv300 40 Mpa (5800 psi)

8.4 g/cm3 (0.303 lb/in3)

2 - 5% 5 – 10 µm 6 - 8 µm Ra

For more information, details, samples or a demonstration of the process, call us on 07 3823 1004, or contact us via email on our Contact Form