Views: 0 Author: Hanna Publish Time: 2025-12-03 Origin: Site
Thermal arc spray wires are the core consumable in the twin-wire arc spraying process – the most popular and cost-effective thermal spray technology worldwide. Two metal wires are fed into a spray gun, an electric arc melts them at over 5,000°C, and compressed air atomizes the molten droplets onto the surface, creating a strong, metallurgically bonded protective coating.
India has emerged as one of the world’s top producers because of abundant raw materials, advanced wire-drawing technology, direct factory pricing, and manufacturers who truly understand the needs of thermal spray contractors.
The process is brilliantly simple: twin wires → electric arc → molten particles → high-velocity impact → instant corrosion and wear barrier. No flames, no expensive powders – just pure efficiency.
Resists scaling and oxidation up to 1200°C, far superior to many other thermal spray materials.
Excellent protection in aggressive environments, including sulfur-containing atmospheres and hot corrosion conditions.
Ideal for heating element coatings that require stable resistance and uniform heat distribution.
Ensures durable coatings on diverse substrates, enhancing reliability in industrial thermal spray applications.
Suitable for multiple spraying methods, with customizable finishes for optimal thermal spray wires performance.
We evaluated production capacity, diameter tolerance, spool quality, MOQ flexibility, real feedback from coating contractors across Mumbai, Chennai, Ahmedabad, Delhi, and export reliability.
If you’re still buying from anyone else, you’re simply paying more than you need to.
DLX Alloy operates one of the largest dedicated thermal spray wire production facilities in Asia, with massive ready-stock warehouses in Mumbai and Chennai exclusively serving the Indian market. This unique manufacturing + local stocking model delivers Chinese-scale pricing with true Indian-speed delivery.
NiAl 95/5 & NiAl 80/20 (the world’s favorite bond coats)
Pure Zinc 99.99%, ZnAl 85/15, pure Aluminum 99.5%
Pure Molybdenum wire, Tafa 75B (NiCr 80/20), 420 SS, Hastelloy equivalents
Custom alloys and cored wires on demand
They control every step – melting, drawing, annealing, spooling – under one roof. No middlemen, no hidden margins.
ISO 9001:2015, ISO 14001, CE marked. Every spool ships with full chemical composition and diameter tolerance certificates. Serious buyers can request free 5 kg trial coils.
Stock in Mumbai & Chennai means 7–15 day delivery to any city in India. They also export regularly to over 40 countries.
A respected name since 1967. They manufacture both arc spray equipment and high-quality wires – especially strong in molybdenum and pure zinc.
Bangalore-based specialists in aluminum and zinc-aluminum wires – a favorite among bridge and storage tank coating contractors.
Primarily known for welding consumables, but their NiAl and stainless thermal spray wires are widely trusted in power and cement plants.
A growing player with excellent pure zinc and aluminum wires for anti-corrosion applications.
Still the undisputed champion for bond coats and self-bonding applications. DLX’s version is famous for flawless feeding and zero oxidation.
The go-to choice for sacrificial corrosion protection on steel structures. ZnAl 85/15 gives you the best of both metals.
Perfect when extreme wear resistance at elevated temperatures is required – think paper mill rolls and boiler tubes.
| Item | Inconel 625 | Ni95Al5 | 45CT | Monel 400 | Monel K500 | HC-276 | Cr20Ni80 |
| C | ≤0.05 | ≤0.02 | 0.01-0.1 | ≤0.04 | ≤0.25 | ≤0.02 | ≤0.08 |
| Mn | ≤0.4 | ≤0.2 | ≤0.2 | 2.5-3.5 | ≤1.5 | ≤1.0 | ≤0.06 |
| Fe | ≤1.0 | N/A | ≤0.5 | ≤1.0 | ≤1.0 | 4.0-7.0 | N/A |
| P | ≤0.01 | ≤0.01 | ≤0.01 | ≤0.01 | ≤0.01 | ≤0.01 | ≤0.02 |
| S | ≤0.01 | ≤0.01 | ≤0.01 | ≤0.01 | ≤0.01 | ≤0.01 | ≤0.01 |
| Si | ≤0.15 | ≤0.2 | ≤0.2 | ≤0.15 | ≤0.5 | ≤0.08 | 0.75-1.6 |
| Cu | N/A | N/A | N/A | rest | 27-33 | N/A | N/A |
| Ni | rest | rest | rest | 65-67 | rest | rest | rest |
| Co | N/A | N/A | N/A | N/A | N/A | N/A | N/A |
| Al | ≤0.4 | 4-5 | N/A | ≤0.5 | 2.3-3.15 | N/A | N/A |
| Ti | ≤0.4 | 0.4-1 | 0.3-1 | 2.0-3 | 0.35-0.85 | N/A | N/A |
| Cr | 21.5-23 | ≤0.2 | 42-46 | N/A | N/A | 14.5-16 | 20-23 |
| Nb | 3.5-4.15 | N/A | N/A | N/A | N/A | N/A | ≤1.0 |
| Mo | 8.5-10 | N/A | N/A | N/A | N/A | 15-17 | N/A |
| V | N/A | N/A | N/A | N/A | N/A | ≤0.35 | N/A |
| W | N/A | N/A | N/A | N/A | N/A | 3.0-4.5 | N/A |
| Impurities | ≤0.5 | ≤0.5 | ≤0.5 | ≤0.5 | ≤0.5 | ≤0.5 | ≤0.5 |
Power generation (boiler tubes), oil & gas (pipelines & valves), infrastructure (bridges & flyovers), cement plants, paper & pulp, marine, and wind energy – Indian wires protect them all.
Small to medium job shops love DLX’s 50 kg MOQ. Large OEMs appreciate their 500–1000 kg reusable drums and consistent 1.6 mm, 2.0 mm, 2.3 mm, and 3.17 mm diameters.
Finer wires (1.2 mm gaining traction), powder-cored wires, robotic spraying systems, and drone-assisted applications for tall structures – all made possible by affordable, high-quality Indian consumables.
Every manufacturer on this list produces good wire. But only one combines world-class metallurgy, the lowest wholesale prices in India, tiny minimum orders, ready stock across the country, and delivery faster than most local suppliers. That one is DLX Alloy. Visit https://www.dlx-group.com/thermal-spray-wire.html today, request your free sample coil, and discover why thousands of thermal spray professionals across India have already made the switch.
DLX Alloy clearly leads in quality, pricing, availability, and customer satisfaction.
DLX Alloy offers just 50 kg minimum and maintains ready stock in Mumbai & Chennai.
Top Indian brands like DLX meet or exceed international specifications while costing 35–50% less.
1.6 mm (1/16") remains the global standard, followed by 2.0 mm and 2.3 mm.
Yes – DLX Alloy can develop and deliver almost any custom alloy within 15–25 days.
4.ISO Certifications & Quality Testing at DLX Alloy
