Engineered Surfaces for Exceptional Performance

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.

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.

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 Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
700-770 Hv300 117 mm3 3.6 g/cm3
(0.13 lb/in3)
8 -12% 8 -12 μm Ra 7 x 10-6/K at 1000°C (1832°F)

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

Features & Benefits

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
900 – 1000 Hv100 32 mm3 3.6 g/cm3 (0.13 lb/in3) 6 – 8% 7 – 9 μm Ra 7.5 x 10-6/K at 700°C (1292°F)

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

Features & Benefits

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
900 – 1000 Hv100 38 mm3 3.6 g/cm3 (0.13 lb/in3) 6 – 8% 7 – 9 μm Ra 7.5 x 10-6/K at 700°C (1292°F)

Black Body Thermal Spray Flexicord

Features & Benefits

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
Cr2O – 55.25%
Al2O3  – 27.1%
SiO2  – 11%
TiO – 6.65%
710 – 920 Hv300 3.9 g/cm3 (0.13 lb/in3) 8 – 10% 5 – 10 μm 56 μm Rz

Blue Corundum Thermal Spray Flexicord (Al2O3 3% TiO2)

Features & Benefits

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
800 Hv300 55 mm3 3.5 g/cm3 (0.126 lb/in3) 6 – 8% 6 – 8 μm Ra 7.5 x 10-6/K at 700°C (1292°F)

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

Features & Benefits

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
1010 Hv200 51 mm3 3.6 g/cm3 (0.13 lb/in3) 4 – 7% 3 – 4 μm Ra 7.5 x 10-6/K at 700°C (1292°F)

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

Features & Benefits

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
950 Hv200 6 mm3 3.6 g/cm3 (0.13 lb/in3) 3 – 6% 3 – 4 μm Ra 7.5 x 10-6/K at 700°C (1292°F)

Spinel Thermal Spray Flexicord (Al2O3 30% MgO)

Features & Benefits

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
730 Hv300 76 mm3 3 g/cm3 (0.10 lb/in3) 10 – 17% 7 – 12 μm Ra 8.8 x 10-6/K at 980°C (1688°F)

Magnesium Zirconate Thermal Spray Flexicord (ZrO2 20% MgO)

Features & Benefits

Physical Properties

Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Coating Roughness CTE
760 Hv300 162 mm3 4.9 g/cm3 (0.17 lb/in3) 10 – 15% 10 – 15 μm Ra 10 x 10-6/K at 1000°C (1843°F)

Titania Thermal Spray Flexicord (TiO2)

Features & Benefits

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss  Coating Density Coating Porosity Pore Diameter Coating Roughness CTE
TiO– 100% 950 Hv300 21 mm3 4.1 g/cm3 (0.15 lb/in3) 3 – 4% 5 μm 4 – 8 μm Ra 8.5 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

Composition Coating Hardness ASTM G65 Volume Loss  Coating Density Coating Porosity Pore Diameter Coating Roughness
Cr2O3 – 99.2%
Other – max 0.8%
935 Hv300 6 mm3 5.2 g/cm3 (0.187 lb/in3) 1% ~5 μm 3 μm Ra

Alumina Supra Thermal Spray Flexicord (Al2O3)

Features & Benefits

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss  Coating Density Coating Porosity Pore Diameter Coating Roughness Resistivity AC Dielectric Strength
Al2O3 – 99.7%
Other – max 0.3%
680 Hv300 36 mm3 3.8 g/cm3
(0.137 lb/in3)
4 – 6% ~2 – 12 μm 3 – 5 μm Ra 2.108 Ω/cm at 700°C (1292°F) 10 – 15 kV/mm

Spinel Supra Thermal Spray Flexicord (Al2O3 30% MgO)

Features & Benefits

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
Al2O3 – 70%
MgO – 30%
1000 Hv300 4 g/cm3 (0.144 lb/in3) 4 – 7% ~5 – 10 μm 7 – 12 μm Ra

AZ Supra Thermal Spray Flexicord (Al2O3 23% ZrO2)

Features & Benefits

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
Al2O3 – 75%
ZrO2 – 23%
Other – 2%
500 – 600 Hv300 4.3 g/cm3 (0.155 lb/in3) 2 – 5% ~5 μm 3 – 5 μm Ra

ZirMag Supra Thermal Spray Flexicord (ZrO2 22% MgO)

Features & Benefits

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
Al2O3 – 78%
MgO – 22%
650 Hv300 5.2 g/cm3 (0.187 lb/in3) 1.8 – 4% 1 – 10 µm 5 – 7 µm Ra

Iron Oxide Thermal Spray Flexicord (Fe3O4)

Features & Benefits

Physical Properties

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
Fe3O4 – 92%
SiO2 – 3%
Other – 5%
810 Hv300 5.1 g/cm3 (0.182 lb/in3) 6 – 8% 5 – 20 µm 12 – 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

Composition Coating Hardness Coating Density Coating Porosity Coating Oxidation Coating Roughness Melting Temp.
Ni 67% Al 10%
Cr 22% Y 1%
250 – 350 Hv300 7.2 g/cm3 (0.26 lb/in3) 5% ~20% 6 – 8 µm Ra 1400°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

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness Melting Temp.
Ni 80%
Cr 20%
280 Hv300 7.25 g/cm3 (0.262 lb/in3) 1 – 3% 5 – 10 µm 6 – 8 µm Ra 1400°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

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness CTE Melting Temp.
NiCrBSiFeC Matrix 38HRC +/- 2
Carbides 370 Hv300
8.1 g/cm3 (0.29 lb/in3) 3 – 5% as sprayed 5 to 15 µm 5 µm Ra 14.1 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

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness Melting 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

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness Melting 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

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness Melting Temp.
WC – 50%
NiCrBSi – 50%
Nickel 60 HRC
Carbides 2000 Hv300
3.52 mm 12 g/cm3 (0.43 lb/in3) <1% as fused <1µm as fused 10 – 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

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Roughness (as sprayed)
Al2O3 ~33%
Ni base ~67%
Matrix 60 HRC 6.7 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

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness
WC – 88%
Co – 12%
1050 – 1200 Hv300 1.8 mm 13.7 g/cm3 (0.13 lb/in3) 3 – 7% 5 – 10 µm 4.5 – 6.5 µm Ra

HardKarb 15 HC Thermal Spray Flexicord

Features & Benefits

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness
WC – 85%
Ni – 10%
Cr – 2.75%
Mo – 2.75%
Fe – 1.15%
Co – 0.45%
1000 – 1100 Hv300 3.4 mm 13.3 g/cm3 (0.48 lb/in3) 3 – 5% 5 – 15 µm 4.5 – 6.5 µm Ra

HardKarb CoCr Thermal Spray Flexicord

Features & Benefits

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness
WC – 85%
Co – 10%
Cr – 4%
700 – 1250 Hv300 1.6 mm 13.3 g/cm3 (0.48 lb/in3) 3 – 4% 5 – 10 µm 4.5 – 6.5 µm Ra

ChromKarb Thermal Spray Flexicord (Cr3C2 25% NiCr)

Features & Benefits

Physical Properties

Composition Coating Hardness ASTM G65 Volume Loss Coating Density Coating Porosity Pore Diameter Coating Roughness
Cr3C2 – 75%
NiCr – 25%
900 Hv300 8.9 mm 7.1 g/cm3 (0.26 lb/in3) 2 – 4% 5 – 10 µm 5.5 – 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

Composition Coating Hardness Coating Density Coating Porosity Pore Diameter Coating Roughness
Co Cr29 W4.5 C1.15 (ST6) 39 – 44 HRC 480 Hv300 8.46 g/cm3 (0.306 lb/in3) 7 % 2 – 15 µm 6 – 8 µm Ra as sprayed

RocDur 625 Thermal Spray Flexicord

Features & Benefits

Physical Properties

Composition Coating Hardness Bond Strength Coating Density Coating Porosity Pore Diameter Coating Roughness
NiCrMoFe 340 Hv300 40 Mpa (5800 psi) 8.4 g/cm3 (0.303 lb/in3) 2 – 5% 5 – 10 µm 6 – 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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