Wire flame spraying is a frequently used method which produces very high-quality results. In the automotive industry, for example, every year hundreds of tonnes of molybdenum is sprayed on shifting forks, synchronizer rings and piston rings. This technique is especially suitable for metallic coating systems.

In wire flame spraying, wire-like coating materials are processed by being continuously melted in the center of a oxy-gas flame, which removes droplet-shaped spray particles using an atomizing gas from the melting zone and sprays them onto the prepared surface. The combustion gases used are acetylene, methane, MAPP gas, propane or hydrogen.

The properties of the coating substances largely match those of the compact material. Specifically, however, the laminated coating structure with its microporosity and the coating layer hardness arising from the anoxidation of the particles forms a repellant structure.

The typical coating materials used are iron-based alloys such as carbon steel, chrome and stainless steels. In addition, non-ferrous metals like aluminum, lead, cadmium, copper, molybdenum, nickel, tantalum, titanium, tin and zinc are used as are non-ferrous alloys such as bronze, brass and white metal.