The GST 5K Wire Flame Spray Gun is a robust machine-mounted combustion wire spray gun designed for automated, high-volume industrial production. Its motorized wire-feed system delivers stable material feeding over a wide operating range, making the gun suitable for both short production runs and continuous coating of large batches.
The GST 5K Wire Flame Spray Gun is a robust machine-mounted combustion wire spray gun designed for automated, high-volume industrial production. Its motorized wire-feed system delivers stable material feeding over a wide operating range, making the gun suitable for both short production runs and continuous coating of large batches.
During wire flame spraying, the coating wire is continuously fed into the center of the gun nozzle and melted by an oxy-fuel flame. Compressed air atomizes the molten material into fine droplets and accelerates them toward the prepared workpiece surface. The process combines high deposition rates with a comparatively simple and economical equipment architecture.
The GST 5K can process both hard and soft spray wires when fitted with the appropriate wire-feed and burner hardware. The current GST configuration supports wire diameters from 0.8 to 4.76 mm and spray rates from approximately 60 to 1400 g/min, depending on wire material, diameter and process parameters. Material utilization can reach up to 90% for suitable applications.
The 5K is intended for integration into automated thermal spray cells, including robotic systems, lathes, traverses and workpiece positioners. Optional internal-bore extensions provide additional flexibility for bearing journals, housings, cylinders and other recessed surfaces.
Key benefits
- Heavy-duty machine-mounted construction for automated industrial wire spraying.
- High spray rates up to approximately 1400 g/min, depending on wire and process configuration.
- Supports both hard and soft spray wires with interchangeable process hardware.
- Motorized wire-feed system provides smooth, stable and repeatable material delivery.
- Material utilization efficiency up to 90% for suitable wire and coating applications.
- High deposition productivity with efficient oxygen, fuel-gas and compressed-air consumption.
- Optional 5XT / 3XT extension modules enable coating of internal bores and recessed surfaces.
- Suitable for robotic cells, lathes, traverses and other automated component-handling systems.
Optional Accessories and Consumables
The GST 5K Wire Flame Spray Gun can be configured with process hardware and control components for different wire materials, fuel gases, spray rates and workpiece geometries.
- Nozzles for selected wire diameters and fuel gases
- Siphon plugs and burner / gas-head components
- Drive rolls, gears and wire-feed components
- Front and rear wire guides
- Air caps and spray-pattern hardware
- 5XT / 3XT extension modules for internal surfaces
- 2W-type wire control / straightening and tensioning equipment
- Gas and air control components for automated system integration
- Replacement seals, O-rings, hoses and maintenance tools
The correct 5K configuration depends on wire alloy and diameter, selected fuel gas, spray rate and part geometry. GST can integrate the gun with MP 3000 process control, robotic handling, wire-management equipment, spray booths and filtration systems as part of a complete coating cell.
Applications
The GST 5K Wire Flame Spray Gun is suitable for high-productivity metallic coatings in production, repair and corrosion-protection applications, including:
- Wear-resistant coatings on synchronizer rings, piston rings and automotive friction components.
- Corrosion-protection coatings using aluminum, zinc and Zn-Al wires on steel components.
- Dimensional restoration of shafts, sleeves, hydraulic rods and worn machine surfaces.
- Tube-mill and galvanized-tubing production applications.
- Bearing and sliding surfaces using bronze, babbitt and other functional metallic wires.
- Paper, pulp and printing-industry rolls and rotating components.
- Internal bores, bearing journals and housings using optional extension modules.
- High-volume coatings for steel, manufacturing, marine, rail and general industrial components.
FAQ
What is the GST 5K Wire Flame Spray Gun used for?
The 5K is designed for automated wire flame spraying in medium- and high-volume production. It is used for wear protection, corrosion protection, functional metallic coatings and dimensional restoration.
What wire diameters can the GST 5K process?
The current GST 5K configuration supports wire diameters from approximately 0.8 to 4.76 mm. The required drive rolls, wire guides, nozzle and gas hardware are selected for the specific wire size and alloy.
What is the spray rate of the 5K?
Depending on wire material, wire diameter and operating parameters, the GST 5K provides a spray rate of approximately 60 to 1400 g/min.
Can the 5K spray both hard and soft wires?
Yes. The gun can be configured for both hard and soft metallic wires. The wire-feed hardware and process parameters are selected according to the mechanical properties and diameter of the feedstock.
Which gases are required for 5K wire flame spraying?
A standard acetylene setup uses oxygen for combustion and compressed air for atomization. Alternative fuel gases can be used with suitable burner and nozzle hardware, subject to process qualification.
Can the 5K spray internal surfaces?
Yes. Optional 5XT and 3XT extension modules allow the gun platform to coat internal bores and recessed cylindrical surfaces. The required length and minimum bore diameter depend on the chosen extension and spray hardware.
What coatings can be produced with a 5K gun?
Typical coatings include aluminum and zinc corrosion layers, steel and nickel-alloy restoration coatings, molybdenum wear coatings, bronze and babbitt bearing layers, and other metallic wire-based functional coatings.
|
Spray rate
|
Approx. 60-1400 g/min, material and parameter dependent |
|
Oxidizer
|
Oxygen (O2) |
|
Gun type
|
Machine-mounted automated wire spray gun |
|
Gun weight
|
Approx. 2.25 kg in reference 5K configuration |
|
Spray angle
|
0° straight spray |
|
Reference process output
|
30 kW |
|
Wire materials
|
Hard and soft metallic spray wires with appropriate hardware |
|
Optional fuel gases
|
Hydrogen, propane, propylene/MAPP or natural gas with suitable hardware |
|
Standard fuel gas
|
Acetylene |
|
Atomizing gas
|
Compressed air |
|
Wire-feed drive
|
Motorized constant-speed / controlled wire-feed system |
|
Acetylene pressure / flow
|
1.4 bar / 30 NLPM |
|
Material utilization efficiency
|
Up to 90% |
|
Wire diameter
|
0.8-4.76 mm |
|
Oxygen pressure / flow
|
4 bar / 100 NLPM |
|
Compressed-air supply
|
6 bar / 0.7 m³/min |
|
System integration
|
Automated / robotic / machine-mounted wire flame spray systems |
|
Compatible platform
|
GST MP 3000 Flame Spray System and engineered wire-spray cells |
|
Internal-bore extensions
|
5XT / 3XT modules, approx. 152.5-915 mm lengths |
|
Process
|
Wire Flame Spray / Combustion Wire Spray |
To purchase a product you like, you need to order it. There are several scenarios for how this can be done.
Choose the product you like and click the "Book now" button. When placing an order, fill out the form. Enter information in the fields: full name, phone number and e-mail. Then the manager will send you e-mail to confirm your consent to make the purchase.
If you have any questions related to the product select the product you like and click the "Ask a question" button. Then fill out the form with contact information and send an application. The manager will contact you for further discussion.
We work with legal entities. And we provide few payment options.
We work on Standard purchasing Contract basis. Payment type depends on product and final customer country/address.
If you have any questions related to the product select the product you like and click the "Ask a question" button. Then fill out the form with contact information and send an application. The manager will contact you for further discussion.
We can deliver your ordered goods with recommended logistic companies on EXW/DDP basis. Delivery time depends on final customer country/address. Terms and conditions can be found in invoice/offer.
Ready to delivery lead time is longer for customized equipment/systems.
If you have any questions related to the product select the product you like and click the "Ask a question" button. Then fill out the form with contact information and send an application. The manager will contact you for further discussion.