High Performance Nickel Base Alloy Ni95Al5 Thermal Spray Coating Wire for Aerospace

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In advanced industries such as aerospace, the demand for materials that can withstand extreme environments is ever-growing. Ni95Al5, a nickel-aluminum alloy, has emerged as a leading choice for thermal spray coatings due to its remarkable properties. This high-performance alloy is widely used in applications where corrosion resistance, thermal stability, and wear resistance are critical. This article provides an in-depth look at the Ni95Al5 thermal spray wire, highlighting its features, applications, advantages, and why it’s a go-to material in aerospace and beyond.

Element	Inconel 625	Ni95Al5	45CT	Monel 400	Monel K500	HC-276	Cr20Ni80	S5420	0Cr25Al5	Ni80A120	Pure Zinc Wire	ZnA15
C	≤0.05	≤0.02	≤0.01	≤0.1	≤0.04	≤0.25	≤0.02	≤0.08	0.36-0.48	≤0.06	≤0.08	-
Mn	≤0.4	≤0.2	≤0.2	2.5-3.5	≤1.5	≤1.0	≤0.1	≤0.06	≤0.1	≤0.4	≤0.7	≤0.75
P	≤0.01	≤0.01	≤0.01	≤0.01	≤0.01	≤0.02	≤0.01	≤0.01	≤0.04	≤0.05	≤0.025	≤0.02
S	≤0.01	≤0.01	≤0.01	≤0.01	≤0.01	≤0.01	≤0.01	≤0.01	≤0.03	≤0.03	≤0.025	-
Si	≤0.15	≤0.2	≤0.2	≤0.15	≤0.5	≤0.08	0.75-1.6	≤1	≤1	≤0.6	≤0.5	≤0.12
Sn	-	-	-	-	-	-	-	-	-	-	-	≤0.001
Pb	-	-	-	-	-	-	-	-	-	-	-	≤0.005
Cd	-	-	-	-	-	-	-	-	-	-	-	≤0.005
Cr	21.5-23	≤0.2	42-46	-	-	14.5-16	20-23	12-14	23.26	≤0.0015	-	-
Ni	Balance	Balance	Balance	65-67	Balance	27-33	-	-	-	≤0.6	≤0.6	Balance
Cu	-	-	-	Balance	Balance	-	-	-	-	-	-	≤0.002
Mo	8.5-10	-	-	-	-	15-17	-	-	-	-	-	≤0.01
Ti	≤0.4	0.4-1	0.3-1.0	2.0-3.0	0.35-0.85	-	-	-	-	-	-	-
Al	≤0.4	4-5	≤0.5	≤0.5	2.3-3.15	-	-	-	-	4.5-6.5	19-20	≤0.001
Fe	≤1.0	-	≤0.5	≤1.0	≤1.0	4.0-7.0	-	-	-	-	-	14-16
Nb	3.15-4.15	-	-	-	-	-	≤1.0	-	-	-	-	≤0.02
Co	-	-	-	-	-	-	-	-	-	-	-	≤0.05
V	-	-	-	-	-	-	-	≤0.35	-	-	-	-
W	-	-	-	-	-	3.0-4.5	-	-	-	-	-	-
Zinc	-	-	-	-	-	-	-	-	-	-	≥99.95	84-86
Impurities	≤0.50	≤0.50	≤0.50	≤0.50	≤0.50	≤0.50	-	-	-	-	-	-

Key Features of Ni95Al5 Thermal Spray Coating Wire

High Corrosion Resistance
One of the standout features of Ni95Al5 is its superior corrosion resistance. The alloy offers excellent protection against oxidation, ensuring long-lasting performance in harsh environments, especially in high-temperature, chemically aggressive settings such as aerospace or chemical processing.
Superior Mechanical Strength
Ni95Al5 exhibits impressive mechanical properties, providing stability and robustness even under elevated temperatures. This makes it ideal for applications where high strength is necessary, such as in the manufacturing of turbine blades and other high-stress components.
Thermal Stability
With its ability to withstand high temperatures without compromising performance, Ni95Al5 is well-suited for environments where temperature fluctuations are common. It maintains its structural integrity in applications like vacuum coating and spark plug manufacturing.
Wear Resistance
Ni95Al5 provides enhanced wear resistance, reducing the frequency of maintenance and prolonging the service life of components. This property makes it invaluable in applications where wear and tear are significant concerns, such as in aerospace and battery production.
Ease of Fabrication
Ni95Al5 can be easily fabricated into various forms, such as wires, strips, and ribbons. Its adaptability allows manufacturers to create customized components for a wide range of applications, adding to its versatility.

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Applications of Ni95Al5 Thermal Spray Coating Wire

Ni95Al5’s properties make it an excellent choice for several demanding applications, including:

Aerospace
The thermal spray wire is used extensively in aerospace for coating components that require both high corrosion resistance and thermal stability, such as turbine blades, exhaust systems, and heat shields.
Vacuum Coating and Electronic Components
Ni95Al5 is ideal for vacuum coating applications, especially in the creation of components like vacuum valves, inner components of electron tubes, and supporting wires in electronic assemblies.
Battery Production
In battery production, Ni95Al5 is used to create components that need to withstand high temperatures and corrosive environments, ensuring long-term performance and reliability.
Spark Plug Manufacturing
The wire is utilized in the manufacture of heating elements and heating spirals in spark plugs, where high-temperature performance and wear resistance are paramount.
Chemical and Industrial Applications
Ni95Al5 is also used in chemical processing industries to manufacture parts that are exposed to corrosive chemicals, making it a valuable asset in corrosion-resistant applications like reactor linings, pipes, and heat exchangers.

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Advantages of Using Ni95Al5 Thermal Spray Coating Wire

High Durability and Long Service Life
Ni95Al5’s corrosion and wear resistance result in a longer service life for coated components, reducing the need for frequent replacements and lowering maintenance costs.
Enhanced Thermal Stability
Its thermal stability ensures that it can maintain performance under fluctuating temperatures, making it a reliable choice for high-temperature applications.
Versatile and Easy to Process
Ni95Al5 is easy to fabricate, allowing manufacturers to create components of various shapes and sizes with minimal processing effort. Its versatility makes it suitable for a wide range of industrial and aerospace applications.
Environmentally Friendly
With its excellent corrosion resistance, Ni95Al5 is also a more environmentally friendly option, reducing the likelihood of material degradation in harsh environments.

Specifications of Ni95Al5 Thermal Spray Wire

Material Composition: 95% Nickel, 5% Aluminum
Form: Wire, Strip, Ribbon, Bar
Applications: Aerospace, Battery Production, Vacuum Coating, Spark Plug Manufacturing, Chemical Processing
Corrosion Resistance: Excellent protection against oxidation and corrosion
Thermal Stability: Performs well at elevated temperatures
Mechanical Strength: Strong mechanical properties even under stress
Fabrication: Easy to process and form into various shapes

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ABOUT US
About DLX ALLOY
CHANGZHOU DLX ALLOY CO, LTD was established in 2002 and has got ISO9001 International Quality Management System Certificate and SGS Certificate. Our factory is professional in researching and producing special alloy material. From melting, drawing, heat treatment, finishing and testing .We offer nickel based, copper-based, and iron-based alloys, including super alloy, welding materials, anti-corrosion alloy, Precision Alloy , FeCrAl alloy, NiCr alloy, CuNi alloy, thermocouple and etc, in the form of wire, strip, ribbon, bar, tube, plate.
About Our factory
Our 12,000㎡ factory is equipped with complete capabilities for research, production, testing, and packaging. We strictly adhere to ISO 9001 standards in our production processes, with an annual output of 1,200 tons. This ensures that we meet both quantity and quality demands. Furthermore, all products undergo rigorous simulated environment testing including high temperature, high pressure, and corrosion tests before being dispatched, ensuring they meet customer specifications. We also provide chemical analysis reports for every FeCrAl alloy, NiCr alloy, and other products purchased.
For all our clients, we offer timely and multilingual after-sales support and technical consulting, helping you resolve any issues swiftly and efficiently.

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FAQ

Q: What is Ni95Al5?
A: Ni95Al5 is a nickel-aluminum alloy containing 95% nickel and 5% aluminum. It is widely recognized for its corrosion resistance, wear resistance, and thermal stability, making it ideal for harsh industrial and aerospace environments.

Q: What are the primary applications of Ni95Al5?
A: Ni95Al5 is used in aerospace (for turbine blades and heat shields), vacuum coating, battery production, spark plug manufacturing, and chemical processing industries, among others.

Q: What are the main benefits of Ni95Al5?
A: Key benefits include high corrosion resistance, superior mechanical strength, thermal stability, wear resistance, and easy fabrication, making it ideal for high-performance applications.

Q: How does Ni95Al5 perform in high-temperature environments?
A: Ni95Al5 maintains its structural integrity and performance at high temperatures, making it suitable for aerospace applications and other high-heat environments.

Q: Is Ni95Al5 easy to fabricate?
A: Yes, Ni95Al5 can be easily processed and formed into various shapes, allowing manufacturers to create customized components for different applications.

Q: How should Ni95Al5 be stored?
A: To prevent corrosion or damage, store Ni95Al5 in a cool, dry place.