The GST MP3000-WS Wire Flame Spray System is a modular industrial thermal spray platform engineered for automated combustion wire spraying. It combines process control, recipe management, wire spray-gun integration, automation interfaces, and project-specific material and gas-supply modules within a single coordinated coating system.
The GST MP3000-WS Wire Flame Spray System is a modular industrial thermal spray platform engineered for automated combustion wire spraying. It combines process control, recipe management, wire spray-gun integration, automation interfaces, and project-specific material and gas-supply modules within a single coordinated coating system.
Unlike standalone manual flame spray equipment, the MP3000 is designed as the process core of a complete production system. It can be integrated with industrial robots or gun manipulators, workpiece positioners, spray booths, exhaust and filtration equipment, and other auxiliary systems according to the component geometry, coating material, production rate, and plant requirements.
The system can be configured for wire flame spraying with the EGD-K/5K heavy-duty gun or a project-specific combination of flame spray modules. GST MCoat™ software provides centralized process management, operating-program control, real-time monitoring, diagnostics, and integration of peripheral equipment.
The MP3000-WS Combustion Wire Spray System is configured as a complete engineered coating platform. The final equipment package depends on whether the application uses wire, powder, or both feedstock formats, as well as on the required automation level and production environment.
The MP3000 Process Control Center coordinates the combustion wire spray process and connected production-cell equipment. Its modular architecture is designed for integration into automated and robotic coating systems and allows the same control concept to be used across different thermal spray technologies.
GST MCoat™ is the process-control software platform used with MP3000 systems. It provides a unified operator environment for controlling flame spray recipes, monitoring the status of connected equipment, managing production programs, and integrating external automation modules.
Main software functions
The gas-supply architecture is configured around the selected flame spray gun. For EGD-K/5K wire spray guns configurations, the process uses oxygen and acetylene/propane together with compressed air for atomization and particle acceleration. Regulators, safety devices, monitoring instrumentation, and process connections are selected according to the final engineered system.
For wire flame spraying, the EGD-K/5K incorporates a heavy-duty wire-feed mechanism with automatic feed-speed control for continuous industrial operation. For powder flame spraying, the material-feed arrangement is configured for the selected powder, required feed stability, and production task. Feedstock selection is confirmed during process engineering.
The complete system can incorporate industrial robots, dedicated gun manipulators, and workpiece positioners. Correctly selected manipulation equipment maintains the required spray distance, angle, traverse speed, and overlap while enabling repeatable coating of complex components.
Depending on the application, the system can be supplied with a soundproof or process spray booth, exhaust and filtration equipment, component fixtures, safety interlocks, and other auxiliary modules. The complete cell is engineered around the coating process, production rate, workpiece dimensions, and site requirements.
Each MP3000 Wire Flame Spray System is individually configured. Selection of the spray gun, feedstock-delivery system, automation, extraction capacity, workpiece manipulation, and process-control functions is based on the coating specification and production requirements.
The current MP3000 wire flame spray configuration supports two principal gun concepts: automated wire flame spraying with the 5K and EGD-K.
The 5K is a heavy-duty wire flame spray gun developed for automated, high-volume industrial production. Its robust wire-feed mechanism is designed to handle both hard and soft spray wires while maintaining smooth and stable material delivery throughout long production cycles.
Automatic wire-feed speed control, high deposition capability, and efficient process-gas consumption make the 5K suitable for repeatable production coating of components that benefit from metallic wire feedstock, including wear, build-up, friction, and corrosion-protection applications.
The Metco EGD-K is a heavy-duty, machine-mounted wire flame spray gun developed for continuous and high-volume automated production. Closed-loop wire speed control provides stable processing and consistent coating quality, while its robust design and efficient gas consumption support reliable industrial operation.
The MP3000 Flame Spray System is intended for industrial applications where reliable process control, repeatable manipulation, and flexible material selection are required. The wire is selected according to the coating material and required surface properties.
In combustion wire spray, metallic wire is continuously fed into an oxygen-fuel flame. Compressed air atomizes the molten wire tip and accelerates the droplets toward the prepared surface. The process is portable and particularly effective for corrosion protection and dimensional restoration.
Zinc, aluminium and zinc-aluminium wire coatings are used to protect structural steel exposed to weather, salts and other corrosive environments. The portability of wire flame systems supports both shop and on-site work.
Wire flame spray is widely used for metallic corrosion-protection coatings on large industrial assets. Aluminium-based coatings are especially relevant to marine and offshore service.
Metallic wires can be sprayed onto worn shafts, journals, bearing areas and related machine elements to restore dimensions or add functional surface properties.
The MP3000 platform is particularly suitable where flame spraying must be integrated into a repeatable production system. Robot or manipulator control, workpiece positioning, recipe management, process monitoring, and exhaust handling can be coordinated within one engineered system.
The system can be configured for wire flame spraying. The current product configuration supports the 5K wire flame spray gun and the EGD-K wire flame spray gun.
Wire flame spraying continuously melts spray wire and atomizes the molten material with compressed air. Powder flame spraying feeds powder into the combustion flame. Wire spraying is well suited to high-deposition metallic coating applications, while powder spraying provides greater flexibility in coating-material composition.
The MP3000 supports the 5K wire flame spray gun and EGD-K wire flame spray gun. Any additional gun configuration should be confirmed during project engineering.
The listed 5K and EGD-K configurations use acetylene/propane and oxygen, with compressed air used for atomization and particle acceleration.
The MP3000 has a modular architecture and can be engineered around different flame spray modules. The final combination of guns, material-feed equipment, gas circuits, and automation is confirmed for each project.
The 5K Wire Flame Spray Gun supports:
Yes. Worn shafts can be restored using wire flame spray, and dimensional restoration is one of the common applications of the process.
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Remote diagnostics
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Supported by MP3000 control architecture |
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Fuel / oxidizer
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Acetylene / Oxygen |
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Automation integration
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Industrial robots, gun manipulators and workpiece positioners supported |
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Thermal spray process
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Combustion wire flame spray |
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Program management
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Saving and recalling process programs |
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Process variants
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Wire flame spray |
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System platform
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MP3000-WS modular thermal spray process platform |
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Compatible spray guns
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EGD-K / 5K Wire Flame Spray Gun |
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User access
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Multi-level access control |
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Real-time monitoring
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Supported |
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Final system configuration
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Project-specific |
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5K wire diameter
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0.8–4.76 mm |
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5K material utilization
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Up to 90% |
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5K spray rate
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60–1400 g/min |
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5K acetylene pressure / flow
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1.4 bar / 30 NLPM |
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5K oxygen pressure / flow
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4 bar / 100 NLPM |
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5K compressed air
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6 bar / 0.7 m³/min |
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Control software
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GST MCoat™ |
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Peripheral integration
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Spray booth, exhaust / filtration, auxiliary equipment and project-specific modules |
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Graphical operator interface with visualization of process parameters.
Spray-gun library for selecting and managing approved equipment configurations.
Remote diagnostics for service and technical support.
Saving and recalling process-control programs.
Monitoring and control of robots, exhaust / filtration equipment, and other external modules.
Multi-level access for Operator, Process Engineer, and Service Engineer roles.
Real-time monitoring and recording of current process parameters.
Maintenance planning and equipment-service management.
Consumables and resource-consumption monitoring.