The GST EGD-K Wire Flame Spray Gun is a heavy-duty, machine-mounted combustion wire spray gun developed for automated, high-volume industrial coating. It is intended for production environments where stable wire feeding, repeatable spray parameters and long continuous operating cycles are required.
The GST EGD-K Wire Flame Spray Gun is a heavy-duty, machine-mounted combustion wire spray gun developed for automated, high-volume industrial coating. It is intended for production environments where stable wire feeding, repeatable spray parameters and long continuous operating cycles are required.
The coating wire is fed through the gun into an oxy-fuel flame, melted at the nozzle and atomized by compressed air. The EGD-K architecture combines a powerful electric wire-drive system with wire-speed monitoring, allowing the process controller to supervise and adjust material feed for consistent coating output. The gun is suitable for both hard and soft combustion-wire materials when equipped with the appropriate wire-feed and gas hardware.
Standard configurations are commonly arranged for acetylene, oxygen and compressed air. With suitable process hardware, the universal gas-head concept can also support alternative fuel gases such as hydrogen, propane, natural gas, MAPP or MPS. Optional high-speed hardware enables reliable spraying of softer wires including aluminum, copper, babbitt, tin and zinc-based materials.
The GST EGD-K is intended for integration with robotic manipulators, automatic traverses, lathes and complete wire flame spray cells. Optional extension modules make it possible to process internal bores and recessed surfaces, while automatic ignition and flame-detection hardware can be integrated for fully automated production cycles.
Key benefits
- Heavy-duty machine-mounted design for continuous, high-volume wire flame spray production.
- Closed-loop wire-speed monitoring supports stable and repeatable coating deposition.
- Powerful wire-drive system provides smooth feed despite changes in wire drag or air pressure.
- Configurable for hard and soft metallic wires, including high-speed soft-wire applications.
- Universal gas-head architecture supports acetylene and alternative fuel gases with suitable hardware.
- High spray productivity combined with economical process-gas consumption.
- Optional extension modules enable coating of internal bores and recessed cylindrical surfaces.
- Service-friendly front-end hardware allows fast replacement of nozzles, siphon plugs and wire guides.
Optional Accessories and Consumables
The GST EGD-K Wire Flame Spray Gun can be configured with interchangeable process hardware, extension modules and maintenance parts according to the wire material, fuel gas, component geometry and production requirements.
- Drive rolls and wire-feed gears for selected wire diameters
- Nozzles for different wire sizes and fuel-gas configurations
- Siphon plugs and gas-head components
- Front and rear wire guides
- Air caps for selected spray patterns and spray angles
- 5XT / 3XT extension modules for internal-bore spraying
- Automatic ignition and flame-detection device
- Process-gas, atomizing-air and wire-drive hose/cable sets
- Replacement O-rings, seals, lubrication and maintenance tools
Extension modules are available in reference lengths of 152.5, 305, 610 and 915 mm. Final nozzle, siphon-plug, wire-guide, gas-head and extension configuration should be selected according to the wire alloy, wire diameter, fuel gas, spray rate and workpiece geometry.
Applications
The GST EGD-K Wire Flame Spray Gun is designed for repeatable, high-volume production coatings and automated restoration processes, including:
- Wear-resistant coatings on synchronizer rings and other transmission components.
- Piston-ring coatings for controlled friction and wear performance.
- Tube-mill and galvanized-tubing production applications.
- Shifter forks and other automotive sliding-wear components.
- Self-lubricating metallic coatings for sliding and bearing surfaces.
- High-volume corrosion-protection coatings on industrial components.
- Internal bores, bearing journals and recessed surfaces using optional extensions.
- Dimensional restoration of worn or undersized shafts, sleeves and machine parts.
FAQ
What is the GST EGD-K Wire Flame Spray Gun used for?
The EGD-K is intended for automated, high-volume wire flame spraying. Typical applications include synchronizer rings, piston rings, tube-mill components, shifter forks, sliding-wear coatings, corrosion protection and dimensional restoration.
How does the EGD-K wire flame spray process work?
Metal wire is continuously fed into an oxy-fuel flame, where it is melted. Compressed air atomizes the molten wire and accelerates the droplets toward the prepared workpiece surface to form the coating.
Which wire sizes can the EGD-K spray?
The reference EGD-K configuration is designed for 3.175 mm and 4.76 mm wire. Other wire applications require the appropriate wire-feed, guide, nozzle and gas-head hardware.
Can the EGD-K spray both hard and soft wires?
Yes. The gun can be configured for hard and soft combustion-wire materials. Softer materials such as aluminum, copper, babbitt, tin and zinc-based wires use dedicated high-speed hardware.
Which fuel gases can be used with the EGD-K?
Acetylene is the standard reference fuel. With suitable gun hardware, the gas head can be configured for hydrogen, propane, natural gas, MAPP or MPS, depending on the coating process and plant utilities.
Can the EGD-K coat internal bores?
Yes. Optional 5XT and 3XT extension modules are intended for internal bores and recessed surfaces. The minimum accessible diameter and required extension length depend on the selected hardware and workpiece geometry.
How is wire-feed consistency controlled?
The EGD-K uses a heavy-duty electric drive and an integrated wire-speed sensor. In an automated system, the controller can monitor wire speed and adjust the feed to maintain stable coating output.
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Oxidizer
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Oxygen (O2) |
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Gun type
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Heavy-duty machine-mounted automated wire spray gun |
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Gun weight
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Approx. 8.5 kg without hoses and cables |
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Spray angle
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0° straight spray |
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Connection orientation
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180° reference configuration |
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Reference process output
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30 kW |
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Wire materials
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Hard and soft metallic combustion-spray wires with appropriate hardware |
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Standard wire sizes
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3.175 or 4.76 mm (1/8 or 3/16 in) |
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Optional fuel gases
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Hydrogen, propane, natural gas, MAPP or MPS with suitable gun hardware |
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Standard fuel gas
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Acetylene |
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Acetylene working pressure
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1.5 bar |
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Atomizing gas
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Dry, oil-free compressed air |
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Wire-feed drive
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Electric variable-speed motor and heavy-duty transmission |
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Oxygen working pressure
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5 bar |
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Wire-speed monitoring
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Integrated speed sensor for closed-loop process control |
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Compressed-air working pressure
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7.5 bar |
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Overall dimensions
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Approx. 370 x 190 x 137 mm |
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Electrical supply
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220 VAC, 50 Hz reference configuration |
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Internal-bore option
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5XT / 3XT extension modules; 152.5 to 915 mm lengths, application dependent |
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Process
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Wire Flame Spray / Combustion Wire Spray |
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