Engineered Surfaces for Exceptional Performance

Flexicord thermal spray consumable

Flexicord is manufactured by co-extrusion of a paste containing the powder material (metallic, ceramic or carbide) and organic skin. It is sprayed through a Flame Spray pistol using Oxygen & Acetylene gases. Flexicord products deliver excellent resistance to thermal cycling, abrasion, corrosion and dielectric exposure. When compared with HVOF and Plasma sprayed coatings, Flexicord consumables impart coatings with less internal stress, allowing thicker coatings with better thermal cycling resistance & wear protection.

Flexicord composition and reels

Thermal spray Flexicord products are available in a range of metallic, ceramic and carbide formulations. Consult our MSSA technical specialists to assist in selecting the right coating for your specific needs.

Flexicord spraying with Master Jet gunFlexicord fuse process with acetylene torch

Spray and Fuse with Flexicord ROCDUR Series for Hard-Facing

Application Examples

Rewinder Rollers – Saint-Gobain Coating Solutions

Aluminium Casting – Saint-Gobain Coating Solutions

Textile Equipment Coatings – Saint-Gobain Coating Solutions

Metal Wire Drawing – Saint-Gobain Coating Solutions

Ceramic Series

The ceramic-based thermal spray Flexicord products are used to increase the life of components exposed to demanding process conditions. Ceramic Flexicord products are available in a range of coating formulations to cover a wide range of applications including resistance to mechanical wear, corrosion, thermal insulation, electrical insulation, diffusion barrier.

Pure Alumina Thermal Spray Flexicord (Al2O3)

Features & Benefits

Physical Properties

Coating HardnessASTM G65 Volume LossCoating DensityCoating PorosityCoating RoughnessCTE
700-770 Hv300117 mm33.6 g/cm3
(0.13 lb/in3)
8 -12%8 -12 μm Ra7 x 10-6/K at 1000°C (1832°F)

Black Corundum 15 Thermal Spray Flexicord (Al2O3 15% TiO2)

Features & Benefits

Physical Properties

Coating HardnessASTM G65 Volume LossCoating DensityCoating PorosityCoating RoughnessCTE
900 – 1000 Hv10032 mm33.6 g/cm3 (0.13 lb/in3)6 – 8%7 – 9 μm Ra7.5 x 10-6/K at 700°C (1292°F)

Black Corundum 50 Thermal Spray Flexicord (Al2O3 50% TiO2)

Features & Benefits

Physical Properties

Coating HardnessASTM G65 Volume LossCoating DensityCoating PorosityCoating RoughnessCTE
900 – 1000 Hv10038 mm33.6 g/cm3 (0.13 lb/in3)6 – 8%7 – 9 μm Ra7.5 x 10-6/K at 700°C (1292°F)

Black Body Thermal Spray Flexicord

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating Roughness
Cr2O3  – 55.25%
Al2O3  – 27.1%
SiO2  – 11%
TiO2  – 6.65%
710 – 920 Hv3003.9 g/cm3 (0.13 lb/in3)8 – 10%5 – 10 μm56 μm Rz

Blue Corundum Thermal Spray Flexicord (Al2O3 3% TiO2)

Features & Benefits

Physical Properties

Coating HardnessASTM G65 Volume LossCoating DensityCoating PorosityCoating RoughnessCTE
800 Hv30055 mm33.5 g/cm3 (0.126 lb/in3)6 – 8%6 – 8 μm Ra7.5 x 10-6/K at 700°C (1292°F)

Ti-Elite Thermal Spray Flexicord (Al2O3 13% TiO2)

Features & Benefits

Physical Properties

Coating HardnessASTM G65 Volume LossCoating DensityCoating PorosityCoating RoughnessCTE
1010 Hv20051 mm33.6 g/cm3 (0.13 lb/in3)4 – 7%3 – 4 μm Ra7.5 x 10-6/K at 700°C (1292°F)

Ti-Tex Thermal Spray Flexicord (Al2O3 40% TiO2)

Features & Benefits

Physical Properties

Coating HardnessASTM G65 Volume LossCoating DensityCoating PorosityCoating RoughnessCTE
950 Hv2006 mm33.6 g/cm3 (0.13 lb/in3)3 – 6%3 – 4 μm Ra7.5 x 10-6/K at 700°C (1292°F)

Spinel Thermal Spray Flexicord (Al2O3 30% MgO)

Features & Benefits

Physical Properties

Coating HardnessASTM G65 Volume LossCoating DensityCoating PorosityCoating RoughnessCTE
730 Hv30076 mm33 g/cm3 (0.10 lb/in3)10 – 17%7 – 12 μm Ra8.8 x 10-6/K at 980°C (1688°F)

Magnesium Zirconate Thermal Spray Flexicord (ZrO2 20% MgO)

Features & Benefits

Physical Properties

Coating HardnessASTM G65 Volume LossCoating DensityCoating PorosityCoating RoughnessCTE
760 Hv300162 mm34.9 g/cm3 (0.17 lb/in3)10 – 15%10 – 15 μm Ra10 x 10-6/K at 1000°C (1843°F)

Titania Thermal Spray Flexicord (TiO2)

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume Loss Coating DensityCoating PorosityPore DiameterCoating RoughnessCTE
TiO2 – 100%950 Hv30021 mm34.1 g/cm3 (0.15 lb/in3)3 – 4%5 μm4 – 8 μm Ra8.5 x 10-6/K at 1000°C (1832°F)

Ceramic Supra Series

The Supra line of ceramic-based thermal spray Flexicord products to increase the life of components exposed to demanding process conditions. The Supra Flexicord line provides denser coatings with lower porosity, smoother finish  after spraying (lower Ra) and finer micro-structure than other Flexicord products.

Supra Flexicord products are available in a range of coating formulations for optimized resistance to mechanical wear, corrosion, thermal shock & thermal cycling. These materials provide excellent diffusion & thermal barrier characteristics as well as electrical insulation properties.

Chromia Supra Thermal Spray Flexicord (Cr2O3)

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume Loss Coating DensityCoating PorosityPore DiameterCoating Roughness
Cr2O3 – 99.2%
Other – max 0.8%
935 Hv3006 mm35.2 g/cm3 (0.187 lb/in3)1%~5 μm3 μm Ra

Alumina Supra Thermal Spray Flexicord (Al2O3)

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume Loss Coating DensityCoating PorosityPore DiameterCoating RoughnessResistivityAC Dielectric Strength
Al2O3 – 99.7%
Other – max 0.3%
680 Hv30036 mm33.8 g/cm3
(0.137 lb/in3)
4 – 6%~2 – 12 μm3 – 5 μm Ra2.108 Ω/cm at 700°C (1292°F)10 – 15 kV/mm

Spinel Supra Thermal Spray Flexicord (Al2O3 30% MgO)

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating Roughness
Al2O3 – 70%
MgO – 30%
1000 Hv3004 g/cm3 (0.144 lb/in3)4 – 7%~5 – 10 μm7 – 12 μm Ra

AZ Supra Thermal Spray Flexicord (Al2O3 23% ZrO2)

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating Roughness
Al2O3 – 75%
ZrO2 – 23%
Other – 2%
500 – 600 Hv3004.3 g/cm3 (0.155 lb/in3)2 – 5%~5 μm3 – 5 μm Ra

ZirMag Supra Thermal Spray Flexicord (ZrO2 22% MgO)

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating Roughness
Al2O3 – 78%
MgO – 22%
650 Hv3005.2 g/cm3 (0.187 lb/in3)1.8 – 4%1 – 10 µm5 – 7 µm Ra

Iron Oxide Thermal Spray Flexicord (Fe3O4)

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating Roughness
Fe3O4 – 92%
SiO2 – 3%
Other – 5%
810 Hv3005.1 g/cm3 (0.182 lb/in3)6 – 8%5 – 20 µm12 – 13 µm Ra

Bond Coat Series

Some applications require a bond coat layer to improve adhesion of thermal spray coatings designed to increase the life of parts & equipment. For this reason, MSSA offer two thermal spray Flexicord materials engineered to improve bond strength between substrate & sprayed ceramic coatings. These Flexicords enhance the coatings’ resistance to corrosion & oxidation in high-temperature applications, thus providing maximum protection in demanding services.

NiCrAlY Bond Coat Thermal Spray Flexicord

This nickel-based thermal spray Flexicord improves the adhesion of the coating to the substrate, thus enhancing the performance of ceramic coatings in demanding services.

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityCoating OxidationCoating RoughnessMelting Temp.
Ni 67% Al 10%
Cr 22% Y 1%
250 – 350 Hv3007.2 g/cm3 (0.26 lb/in3)5%~20%6 – 8 µm Ra1400°C (2552°F)

NiChrome Thermal Spray Flexicord (NiCr)

This nickel-chromium thermal spray Flexicord improves the adhesion of the coating to the substrate, thus enhancing the performance of ceramic coatings in demanding services.

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating RoughnessMelting Temp.
Ni 80%
Cr 20%
280 Hv3007.25 g/cm3 (0.262 lb/in3)1 – 3%5 – 10 µm6 – 8 µm Ra1400°C (2552°F)

RocDur Series

RocDur series of thermal spray Flexicord deliver high-quality, cost effective coatings for flame spray application, either as sprayed or as fused. Made of a nickel self-fluxing alloy, RocDur thermal spray Flexicord are available in a range of wear-resistant compositions with matrix hardness from 19 HRC to 62 HRC. Whichever formula meets your specific needs for corrosion resistance, wear resistance or, RocDur thermal spray Flexicord offer excellent coating efficiency, enabling users to save time & money.

RocDur 44 Thermal Spray Flexicord

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating RoughnessCTEMelting Temp.
NiCrBSiFeCMatrix 38HRC +/- 2
Carbides 370 Hv300
8.1 g/cm3 (0.29 lb/in3)3 – 5% as sprayed5 to 15 µm5 µm Ra14.1 x 10-6/K at 700°C (1292°F)1060°C (1940°F)

RocDur 6728 Thermal Spray Flexicord

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating RoughnessMelting Temp.
WC – 28%
NiCrBSi – 72%
Matrix 60HRC
Carbides 1300Hv300
10.1 g/cm3 (0.36 lb/in3)<1% as fused<1µm as fused–212.5 µm Ra as sprayed
2 – 4 µm as fused
1060°C (1940°F)

RocDur 6740 Thermal Spray Flexicord

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating RoughnessMelting Temp.
WC – 40%
NiCrBSi – 60%
Matrix 60HRC
Carbides 1300Hv300
10.1 g/cm3 (0.36 lb/in3)<1% as fused<1µm as fused–212.5 µm Ra as sprayed
2 – 4 µm as fused
1060°C (1940°F)

RocDur 6750 Thermal Spray Flexicord

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume LossCoating DensityCoating PorosityPore DiameterCoating RoughnessMelting Temp.
WC – 50%
NiCrBSi – 50%
Nickel 60 HRC
Carbides 2000 Hv300
3.52 mm3 12 g/cm3 (0.43 lb/in3)<1% as fused<1µm as fused10 – 12 µm Ra as sprayed
0.25 – 0.4 µm as fused
1060°C (1940°F)

RocDur NS 60 Thermal Spray Flexicord

A nickel/tungsten carbide based product from our line of thermal spray Flexicord products.

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume LossCoating DensityRoughness (as sprayed)
Al2O3 ~33%
Ni base ~67%
Matrix 60 HRC6.7 mm3 5.8 g/cm3 (0.21 lb/in3)19 µm Ra
143 µm Rmax
73 µm RP
147 µm Rt

Carbide Series

MSSA carbide series of thermal spray Flexicord materials produce high performance tungsten carbide or chromium carbide coatings. These coatings provide resistance to abrasion, erosion, fretting & sliding wear comparable to those produced by costlier HVOF methods.

Compared to HVOF or plasma sprayed coatings, the carbide series Flexicord products yield coatings with less internal stress which permits thicker coatings & better resistance to thermal cycling. The coatings can be used as sprayed – with roughness values from 4 – 6.5 μm – or can be finished with diamond or AZ grinding.

HardKarb 12 Co Thermal Spray Flexicord

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume LossCoating DensityCoating PorosityPore DiameterCoating Roughness
WC – 88%
Co – 12%
1050 – 1200 Hv3001.8 mm3 13.7 g/cm3 (0.13 lb/in3)3 – 7%5 – 10 µm4.5 – 6.5 µm Ra

HardKarb 15 HC Thermal Spray Flexicord

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume LossCoating DensityCoating PorosityPore DiameterCoating Roughness
WC – 85%
Ni – 10%
Cr – 2.75%
Mo – 2.75%
Fe – 1.15%
Co – 0.45%
1000 – 1100 Hv3003.4 mm3 13.3 g/cm3 (0.48 lb/in3)3 – 5%5 – 15 µm4.5 – 6.5 µm Ra

HardKarb CoCr Thermal Spray Flexicord

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume LossCoating DensityCoating PorosityPore DiameterCoating Roughness
WC – 85%
Co – 10%
Cr – 4%
700 – 1250 Hv3001.6 mm3 13.3 g/cm3 (0.48 lb/in3)3 – 4%5 – 10 µm4.5 – 6.5 µm Ra

ChromKarb Thermal Spray Flexicord (Cr3C2 25% NiCr)

Features & Benefits

Physical Properties

CompositionCoating HardnessASTM G65 Volume LossCoating DensityCoating PorosityPore DiameterCoating Roughness
Cr3C2 – 75%
NiCr – 25%
900 Hv3008.9 mm3 7.1 g/cm3 (0.26 lb/in3)2 – 4%5 – 10 µm5.5 – 6 µm Ra

Special Alloy Series

MSSA offer thermal spray Flexicord products in two non-magnetic alloy formulations:

Corec 6 Thermal Spray Flexicord

Features & Benefits

Physical Properties

CompositionCoating HardnessCoating DensityCoating PorosityPore DiameterCoating Roughness
Co Cr29 W4.5 C1.15 (ST6)39 – 44 HRC 480 Hv3008.46 g/cm3 (0.306 lb/in3)7 %2 – 15 µm6 – 8 µm Ra as sprayed

RocDur 625 Thermal Spray Flexicord

Features & Benefits

Physical Properties

CompositionCoating HardnessBond StrengthCoating DensityCoating PorosityPore DiameterCoating Roughness
NiCrMoFe340 Hv30040 Mpa (5800 psi)8.4 g/cm3 (0.303 lb/in3)2 – 5%5 – 10 µm6 – 8 µm Ra

Related Powder Consumables

For related powder consumables, view our  Laser Cladding Powders.

For more information, details, samples or a demonstration of the process, call us on 07 3823 1004, or contact us via email on our Contact Form.

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